Setting new standards for commercial windows

John Duckworth, Deceuninck Head of Commercial Sales says the latest window technology and expertise are pushing the boundaries for commercial windows.

In recent years there have been significant advances in window technology which give developers and specifiers a choice of materials, styles and designs to choose from. The very best of this window technology, when combined with advice and guidance from experienced windows suppliers, synchronises perfectly with modern construction methods to create the right aesthetics, reduce installation time, and improve the development’s overall performance.

Deceuninck is the commercial fenestration expert
We are a window systems company with strong ties in the commercial sector. Our flagship commercial 5000 window with Linktrusion™ technology is a popular choice with developers because it gives a true alternative to aluminium. Linktrusion offers the best attributes of aluminium and PVC-U in one system, combining pultruded glass-fibre with PVC-U for strong but light windows with slim sightlines and outstanding thermal efficiency. When used with Deceuninck’s Decoroc colour finishing system, it’s hard to distinguish it from aluminium in looks, touch or performance.

Commercial partnerships
Deceuninck windows and doors are engineered to create the perfect symmetry and balanced sightlines that translate into beautiful looks and performance, combined with outstanding security, energy efficiency and weather performance. But product is just half the story and Deceuninck’s strength in the commercial sector comes from our ability to work with all parts of the supply chain and give advice in the early stages of product specification. We work with a number of prestigious developers including Berkeley Group, Crest Nicholson, Countryside Properties, Weston Homes and Catalyst Housing, offering bespoke service and support. Our commercial and technical teams and partner fabricators have extensive experience in off-site, modular and steel frame construction and we offer guidance on the interface of windows in modern construction methods, working with EPDM suppliers such as Tremco at specification stage. We work closely with developers, specifiers, fabricators and contractors to see the full picture of how windows work within the build, be it timber frame, steel frame or modular, to ensure products meet technical specifications and are correctly installed and perform effectively in the finished project.
Our ability to work closely with supplier and end client to provide a full design solution was highlighted in the recent Springfield Park development with Weston Homes. This was a complex development of over 300 apartments in one tower and three low storey blocks. It incorporated a concrete frame construction with the windows fitted on front of the frame in steel brackets, followed by EPDM shrouding. Deceuninck’s commercial and technical teams worked with window fabricator FastFrame to provide the technical information required for the interface and correct installation of the windows. Our Linktrusion 2500 Fully Reversible Window (FRW) in Decoroc Quartz Grey successfully broke the original specification for aluminium because it combined slim, contemporary profiles with outstanding thermal and acoustic performance. The development, close to roads, railways and the river Thames called for acoustic windows to minimise the impact of external noise and low U-Values to meet stringent energy requirements. Deceuninck’s FRW comfortably met these requirements with decibel reductions in the mid-40s and U-Values as low as 1.3 W/m2K.

Experts in modular developments
Deceuninck has experience in modular developments and the Hinkley Point Worker Accommodation development showcased our expertise. This was a technically demanding project in which 80% of the 1,400 windows were installed into pre-fabricated modules off-site. Working in partnership with fabricator Dempsey Dyer, Deceuninck’s technical team ensured our Tilt and Turn windows met the highest energy and weather requirements both off-site and in installation. Once assembled, the windows passed the most stringent CWCT water testing, normally only used for curtain walling. Our technical team worked with Dempsey Dyer to successfully cut the windows’ decibel rating down by RW35db to RW40db and RW43db, helping to minimise the impact of noise on workers to make a quieter, healthier environment.
More recently, Dempsey Dyer is supplying Deceuninck’s 2500 series windows for university student accommodation. This modular construction project in conjunction with a major international developer will see the windows shipped to Morocco for installation in a modular factory, with further commissioning on site in the UK. Together with Dempsey Dyer, we’ve facilitated this project by giving advice on design, purge ventilation and interface detail. Dempsey Dyer is also sending a team to Morocco to train workers on effective modular installation. It’s an exciting project and we predict the strong trend for modular construction will continue to grow.

Call 01249 816 969 or visit the website to see more commercial case studies and learn more about our commercial work. You can also download Deceuninck’s full product portfolio from the NBS National BIM Library at:

www.nationalbimlibrary.com/deceuninck-ltd

 
www.deceuninck.co.uk

 

 

 

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Modern methods for modern developers

In recent times, three major themes have emerged for developers: satisfy the urgent demand for homes, minimise environmental impact, and how best to make those homes more efficient or “smarter”.

 

Water Services on Tap – The business benefit of plug and play systems

Despite the industries best efforts to meet housing demand, on site delays can impact schedules and completion dates. With utility connections often the weak in project schedules.
Water supply is perhaps the most important item within the critical path of construction and is probably the most difficult to achieve. Imagine a situation where your services can be fully installed, with surface mounted meters allowing ‘plug and play’ style installation.
With Groundbreaker water management system, you have that ‘plug and play’ option – no need to imagine.
The only system of its type, it is designed to be installed at any time during the construction period.  Fully compliant with Water Regulations, it provides an accessible, safe and secure location for the water meter and controls to a specific property.
The concept is simple.  Water services are connected to an externally mounted, pre-installed water service controls.  This allows flexibility in the management and scheduling of connection to the mains supply.  For modular build projects the pre-installation and certification of plumbing can facilitate early approval of water services to a plot.
There is no need for boundary boxes or meter housings in the footpath, and this simplification of the connection allows for improved efficiency and reduces the time required for highway closures and cost of reinstatement.

Design out leak paths:

Comply with Water & Construction Industry Guidelines with “Water Safe” initiatives
The unique location of the Groundbreaker water management system allows for an unjointed water supply, minimising the risk of developing future leaks.  Installation of Groundbreaker meets the best recommendations of Water UK and the Home Builders Federation1 and in some water company areas, such as Portsmouth Water, are now the standard required for all new properties.

Future proof properties

Water Metering is the future.  Utility companies have not been slow in recognising the benefits of a ‘Smart Home’.  The ability to interrogate and manage energy usage at any given time of day or night has been recognised as an effective way for householders to reduce usage and manage costs
Gas and electricity meters located on external building walls has enabled easy upgrades and introduction of countrywide ‘Smart Meter’ programme.  However, the traditional location of a water meter in a metal-covered hole in the public highway is not conducive to this new way of thinking. A ‘Smart Water Meter’ located in such a situation is exceedingly poor in transmitting a signal even to a local pick up.
The best location for a ‘Smart Water Meter’ is on an external property wall  – co-located with other utility meters. With Groundbreaker water management system, properties are future proofed to allow for easy installation of ‘Smart Water Meter’ technology as it is introduced across the UK.
Recent field trials of Groundbreaker have proven that the range of such meters can be over 3Km (2 miles).  The impact on data collection is massive.  The improved data transmission range could allow for single point data capture in towns the size of Norwich or Coventry.
Bringing Water Supply into the 21st century
If you are looking for a way to bring water services into the 21st century, Groundbreaker’s range of water supply management products can be the way forward for time and cost efficient installation and replacement of water supply.

For futher information on the Groundbreaker water management system visit:
www.groundbreaker.co.uk

 

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The 19mm Collated Screw System for Flooring Is Here!

Floor fitters and home owners alike will be all too familiar with the curse of squeaky floorboards. Time after time the culprit is the fasteners; nails working loose over time, leading to expensive callbacks and customer dissatisfaction.

While it’s well known that screws provide a tighter grip power by pulling the boards together, fitting 6mm plywood to underlay has long presented a dilemma. The conventional 25mm timber screws used to fasten flooring carry a risk of damaging underfloor electrical cables or puncturing water pipes, with potentially dangerous and costly consequences, however the alternative use of 19mm nails can cause the plywood subfloor to lift from the floorboards.

Construction products manufacturer Simpson Strong-Tie has developed an affordable solution to the problem, which enables floor fitters to opt for the superior holding power of screws now with the groundbreaking new collated MTHZ19E underlayment screw.  Designed for the Quik Drive auto-feed screw system, the MTHZ19E allows fast and secure underlayment to subfloor installations, with a sharp point for fast start and a trim head for a neat finish. This new shorter length alternative to traditional flooring screws prevents the tip from protruding through the floor boards when fixing 6mm plywood, making it a safer way to fix 6mm plywood to subfloors.

The MTHZ19E can be used to fix to timber joists, or to fix to steel up to 0.9mm thick – for example in the installation of computer flooring, and can be easily removed and reapplied if access required to pipework at a later date. Nailed floorboards are notoriously difficult to remove intact.   While nail guns traditionally provide speed of fastening, they can produce inaccurate results and an inconsistent finish. The Quik Drive system provides a neat finish, with a flush consistent counter sink. And its ergonomic upright installation option will protect your knees and back, with no need to bend or crouch.  Quik Drive features a square drive for improved connection between bit and screw ensuring smoother drive. Nibs under the screw head help countersink into plywood giving a flush finish preventing floor coverings from settling in countersink recesses, and the intricate high low thread has been designed for stronger grip in timber and help prevent floor squeaks.

“In a competitive market client satisfaction is key to gaining repeat business. We all know that nailing is quicker however, I think this short term gain can be costly in the long run” explains Simpson Strong-Tie National Fasteners Sales Manager Natalie Dixon.
“Our flooring clients have told us many times over the years that a shorter collated screw is desperately needed and certainly preferable.
I have been told this issue with snagging a water pipe may not be initially visible. It can leak for days or months or even more causing substantial damage and costs in leak detection. Certainly now avoidable. Penetrating an electrical service pipe could be life threatening. Suddenly, squeaky floorboards may be the least of concern!
“So how do sub-contractors justify the time and slightly extra cost of a screw fixing when it is often the subby that is working on the tightest of margins with little room for error? We understand this is vital to our customers.
“Other collated systems can have up to 10% of the screws in a strip fail. It’s costly, fiddly and an interruption to getting the job done and moving on to the next. Our tests showed that Quik Drive and the MTHZ19E screw had very few (if any), failed screws. Much less than one screw in 50 in fact.”
“Simpson Strong-Tie is a global leader in construction products and we simply do not put our name to anything less than excellence. Knowing the product development that has led to this release – I have no problem standing behind this product with 100% commitment and understanding that it will save our customers time and money.”

The MTHZ19E screws are collated on flat tape, which is different to the usual Quik Drive collation, so there is also a brand new QDBPC19EF Quik Drive 19mm flooring screw attachment available to run the screw through; precision-engineered and is manufactured to the highest standards for guaranteed quality, performance and reliability.

Less torque. Less time. More fastening.

 

Demand for our MTHZ19mm Quik Drive System is already very high. Call Natalie on 07971147961 for information on your nearest stockist or to book a demonstration.

www.strongtie.co.uk

 

 

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DIGITAL FABRICATION

CLICK TO VEIW THE VIDEO

Students at ETH zurich have used innovative technology to create an extremely lightweight pavilion using bamboo. The project demonstrates the possibilities of digital fabrication combined with natural construction materials such as bamboo — a rapidly renewable and high-​quality raw material. Bamboo can be compared with hardwood species, but due to its hollow core, is extremely light-​weight and elastic. It is for this reason that bamboo has been used for centuries in earthquake-​prone areas of Asia.

Visually reminiscent of the arch of a gothic cathedral, but based on state-​of-the-art technology, the digital bamboo pavilion was designed and built by ETH zurich students of the MAS in architecture and digital fabrication (masdfab).  The students used bamboo to create a pavilion weighing just 200 kilograms (440 lbs). Spreading in three directions to cover a total area of more than 40 square meters (430 square feet), its minimal supports contribute to the ethereal nature of the structure. This design-​to-fabrication process depends on digital technologies, using purpose-​made digital design tools to generate this ultralight yet complex structure in earthquake-​prone areas of Asia.

More than 900 bamboo poles have been connected through digitally designed joints and manufactured with sub-​millimetre accuracy in high-​strength nylon and stainless-​steel using 3D printing technologies. Digital fabrication enables all parts to be generated automatically and developed to meet all mechanical requirements. This included not only the complex geometry and structural specifications for each joint, but also the tolerances required for the non-​standard assembly of this natural material. Added to these connections are hinge plates, cables, and anchors — resulting in a total of 379 connections and a very large number of small parts.

The five-​meter-high (16 ft.) pavilion creates protective shade with precise and detailed textile panels that extend the intrinsic pattern of the structural elements. With this in mind, the students designed elements to be 3D printed using a recyclable, UV-​resistant, and malleable plastic onto a lightweight Lycra textile. 3D printing locally reinforces the base material, transforming it into bespoke resistant and flexible shading panels.

‘The construction system developed for this project aims to reduce the logistical effort in construction, demonstrating how advantages of digital fabrication contribute to a more sustainable building culture,’ explains marirena kladeftira, doctoral student at the chair of digital building technologies, who is researching the potential of 3D-​printed connections for innovative and sustainable space frame structures for architecture.

The team behind the project says that this approach could be used wherever bamboo is available and produced in a cost-​effective manner. Furthermore, the design-​to-construction process developed for the bamboo pavilion could even be applied to other materials. Thanks to the modular design, the structure can be assembled and disassembled extremely quickly.

The digital bamboo pavilion was assembled on-​site at the Zurich architecture centre (ZAZ) in just 48 hours in summer 2020, before being disassembled in the same short time. Though the project is no longer on exhibit at the ZAZ, the team hopes that it may soon go on tour including a prolonged stop at the ECC exhibition in Venice, in marinades’ gardens from may to October 2021.

 

Source: Design Boom

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DARWIN DELIVERS

The £7.6m community assessment unit will deliver a new type of healthcare and is designed to help reduce emergency admissions. It will also ensure older patients can return home more quickly and with an appropriate care plan in place.

The handover marks the completion of the project delivered by Shrewsbury-based firm Darwin Group, specialists in offsite construction.

Despite the operational challenges posed by the Covid-19 pandemic, Wrightington, Wigan and Leigh Teaching Hospitals NHS Foundation Trust (WWL) has continued to work on this project which will be managed by the its community services division, supported by health partners across the borough.

The new community assessment unit

This major investment will see the introduction of 21 new community beds, including nine single rooms, with a further six assessment chairs.

It comes as the community team has developed new ways of working which focus on encouraging patient enablement and independence.

Silas Nicholls, chief executive of WWL, said: “The handover is an important milestone for the project to deliver what will be a vital component in our ability to provide the right care, in the right place, at the right time.

“The community assessment unit will help ease the pressure on admissions, particularly in the winter months, and meet the needs of our ageing population in terms of providing additional support for those patients where hospital admission can be avoided and the appropriate care plan for recovery in their own home or residential setting.

“It has been an immense task to deal with the demands of the Covid-19 pandemic, but our community, support staff and Darwin Group have shown incredible commitment and resilience to reach this stage and we are delighted to formally take possession of the unit.”

Alan Davidson, healthcare director at Darwin Group, said: “We are proud to have been able to work with the trust and to deliver such high-quality ward accommodation. Not only will this provide much-needed additional patient accommodation and storage space for the whole site, but we have also future-proofed the building so it can be added to vertically if needed, giving the trust a potential solution to address future service demand.

“Our site team’s management of health and safety and our use of modern methods of construction have allowed us to work without interruption and deliver the project during national lockdowns, while meeting social distancing requirements and industry best practice. We are really pleased at how our team has pulled together to complete this project and overcome all challenges ensuring the safety of each other and everybody involved with the project.”

Philip Bliss, divisional medical director for community services, added: “The community assessment unit is a new venture for WWL. It is the first purpose-built, community-focused unit on the RAEI site, dedicated to the holistic assessment and treatment for some of the more frail and elderly patients coming through our services.

“It is very much focused on a reablement approach, to allow patients to return to their own home environment in a safe and supported manner. This will enable patients to make the most of their potential to continue to live an independent and fulfilling life.”

The unit is on the site of the former pathology lab and will have links physically and operationally to the hospital. It will be officially opened next month.

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Steps to rebuild construction recruitment plans for 2021

by Womble Bond Dickinson

 

The construction industry was quick to adapt and carry on working in 2020, but it continues to struggle with labour levels. And this is a problem that’s not going away any time soon as, due to Brexit and the new immigration system now in place, we are likely to see a reduction in the number of available EU national workers – workers which the industry has traditionally relied upon.

Figures released by the Office for National Statistics (ONS) reveal that up until now more than nine per cent of the UK construction industry workforce have been EU nationals, with that rising in London to account for 30 per cent of construction workers.

Many EU nationals have now returned to their home nations to be with family and to cut the cost of living. New immigration rules are set to be extremely challenging with regard to the sector’s recruitment process and migrant worker eligibility in 2021, meaning it is likely to be more difficult to get these workers back to the UK.

The impact is two-fold. An increased labour shortage could affect the ability of companies to deliver projects on time or to take on new work, and it’s likely that the cost of labour will go up, both in terms of wage levels and also taking additional costs of recruitment and training into account.

While it seems the construction sector is frequently calling for additional Government support to bridge the skills gap, there are some practical steps that employers and contractors themselves can take to mitigate the long-term risks.

Brexit-proof your recruitment process

The new UK points-based immigration system kicked in on 1 January 2021 and it’s highly likely that this will reduce the number of lower skilled workers coming to the UK. Increased bureaucracy, and lead times, around the new points-based immigration system will create delays in the short-term. Get your recruitment process Brexit-compatible by understanding and implementing new visa criteria and processes, and be prepared to factor longer recruitment lead times into project planning.

Keep up-to-date on Government guidance

It’s important to keep on top of the latest Government guidance on matters such as health and safety. Encourage consistent use of personal protective equipment (PPE), and ensure the team feels safe. This will not only encourage productivity and minimise absence due to sickness or injury, but is also likely to have a positive impact on staff retention in a competitive market place.

Reflect on lessons learned during the pandemic

Take time out to understand the lessons learned by the sector during the pandemic. Some construction companies have found that by carefully planning and reorganising their programmes and how some jobs are carried out, and by being more focused on critical path activities, work could still be carried out efficiently and effectively, even with fewer than normal workers on site.

The post-pandemic rise in technology take-up and use has changed the way manual roles are carried out too. For example, some companies are carrying out site inspections with drones, allowing for safer remote-working and more efficient processes. Drones are also being used for 3D modelling, volume measurement and topographical surveys, and are predicted to fulfil an essential role in construction companies of the future, from planning to build. This in itself means a new set of skills is now required for the industry.

Similarly, there has been increase in the use of offsite, modular construction during the pandemic, which again requires a development in design skills and logistics expertise.

Look to youth

Figures released by the Office of National Statistics in October 2019 show there were 334,332 skilled construction and building trade workers aged between 50 and 64 and 44,681 over 65 in the UK – most of whom will typically be expected to retire over the next 15 years.

Meanwhile, the industry is struggling to attract young people. This is not a new problem: in 2018 it was widely reported that construction had, for the first time, dropped out of the top 10 career choices for people aged 22-29. According to YouGov Omnibus research in 2015, only three per cent of young people aged between 18-24 have recently searched for a job in the construction industry.

Construction firms do still have the opportunity to take advantage of Government incentive payments for the hiring of new apprentices, though this scheme only applies to apprentices hired before March 31 2021.

Perhaps, then, it will fall to the construction industry itself to do more to appeal to young people, or the skills shortage might never be fully bridged and critical skills that need to be passed on to a new generation of workers could be lost.

Embrace equality, diversity and inclusion

It is also worth broadening the scope of which parts of society future workers could come from to help improve the number of workers and breadth of skills in the industry.

Women remain under-represented in construction: in Q2 2020, there were 1.9m men in the industry in the UK compared with 289,000 women. Research by Microsoft reveals that in the UK, girls have a five-year window between 11 and 16 when they are really interested in STEM (science, technology, engineering and maths) after which their interest drops.

The industry also under-employs BAME (black, Asian and minority ethnic) groups. Exact levels of BAME employment in construction vary according to different sources, though one report suggested around 7.4 per cent of construction workers identified as BAME.

Figures released by the Government’s Ethnicity Facts and Figures Service in 2020 took a different approach, and analysed the percentage of ethnic groups that work in each industry sector. While 7.7 per cent of surveyed White British people worked in construction, the figures were lower for Asian (3 per cent), Indian (3.8 per cent), Black (4 per cent) and Pakistani & Bangladeshi (2.5 per cent) groups in the UK.

With the UK’s pool of talent more diverse than ever, it is important that companies make a conscious shift towards diversifying their workforce now.

Become UK industry champions

The sector needs to inspire the workforce-of-the-future by engaging with schools, colleges, industry leaders and training bodies to shake up the traditional image of the construction site and wider construction industry. Apart from the digitalisation of the industry, the sector is encouraged to recruit younger generations and minority groups to help fulfil future skills needed.

About re:build Britain

There are significant challenges for the construction sector in 2021 – but huge opportunities as well. We have launched our re:build Britain campaign to help companies in a number of sectors to navigate the next year, and beyond, successfully. Our key focus sectors will include: construction, built environment, free ports, energy and connectivity & digitalisation.

The campaign is kicking off with construction. There are major risks presented by delay and disruption, including materials shortages, contract disputes and staff shortages, and we are here to help you avoid or mitigate those risks.

However, there are huge opportunities as well – construction will be the beating heart of any economic recovery. Throughout our re:build Britain campaign we will offering grounded and practical advice to make sure your business is in the best possible shape to prosper.

After examining delay and disruption, we will look at risk and regulation, commercial and city, people and skills, modern methods of construction, digitisation and future trends.

We have launched the campaign with an easy-to-read guide to mitigating the effects of delay and disruption, which you can download here.

Source: FE News

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192 MMC houses on flood zone

Land at the rear of Bexhill Road in Bulverhythe is the proposed site.

A spokesman said: “The scheme will provide a range of much needed quality housing including a significant number of affordable homes for local families.”

Cllr Andy Batsford, lead councillor for housing and homelessness, said: “We are thrilled to have submitted this exciting planning application to build 192 much needed new homes for the town.

“It’s our intention that as many homes as possible will be built using modern methods of construction so as to help minimise the scheme’s carbon footprint and to get homes built quickly.

“We believe that this development will help demonstrate how high quality and energy efficient housing can be provided for local families whilst minimising any impact on climate change. The application submitted follows extensive consultation with local residents and wider stakeholders which started over 12 months ago.

“We have been awarded up to £6.9m in government funding to remove the barriers to developing the site, which is a huge benefit to the town. Although the site is currently classified as Flood Zone 3b, we have undertaken extensive flood modelling which we believe demonstrates that the site is suitable for housing development. The flood defences that we will employ will not only protect the new homes but will also protect the existing houses and businesses on Bexhill Road and beyond that might otherwise flood.”

He added: “We intend this to be a high-quality development which will provide much needed new homes to help meet our housing crisis. We hope to create a sustainable community where families want to live and which makes a positive contribution to the local area.

“We are looking at how to encourage sustainable transport solutions on the site, including electric vehicle charging points and car clubs. We aim to ensure the development will be pedestrian and cycle friendly.

“There will also be wider benefits, including the replacement of redundant sports pitches to Sport England standards, ecological enhancements and much needed training and employment opportunities while the houses are being built.”

 

Source: Hastings Observer

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LOBSTER STRENGTH

Concrete 3D printed in patterns inspired by the internal structure of lobster shells.

 

Bio-inspired: How lobsters can help make stronger 3D printed concrete

New research shows that patterns inspired by lobster shells can make 3D printed concrete stronger, to support more complex and creative architectural structures.

Digital manufacturing technologies like 3D concrete printing (3DCP) have immense potential to save time, effort and material in construction.

They also promise to push the boundaries of architectural innovation, yet technical challenges remain in making 3D printed concrete strong enough for use in more free-form structures.

 

CLICK TO WATCH THE VIDEO

 

In a new experimental study, researchers at RMIT University looked to the natural strength of lobster shells to design special 3D printing patterns.

Their bio-mimicking spiral patterns improved the overall durability of the 3D printed concrete, as well as enabling the strength to be precisely directed for structural support where needed.

When the team combined the twisting patterns with a specialised concrete mix enhanced with steel fibres, the resulting material was stronger than traditionally-made concrete.

Lead researcher Dr Jonathan Tran said 3D printing and additive manufacturing opened up opportunities in construction for boosting both efficiency and creativity.

“3D concrete printing technology has real potential to revolutionise the construction industry, and our aim is to bring that transformation closer,” said Tran, a senior lecturer in structured materials and design at RMIT.

“Our study explores how different printing patterns affect the structural integrity of 3D printed concrete, and for the first time reveals the benefits of a bio-inspired approach in 3DCP.

“We know that natural materials like lobster exoskeletons have evolved into high-performance structures over millions of years, so by mimicking their key advantages we can follow where nature has already innovated.”

 

3D printing for construction

The automation of concrete construction is set to transform how we build, with construction the next frontier in the automation and data-driven revolution known as industry 4.0.

A 3D concrete printer builds houses or makes structural components by depositing the material layer-by-layer, unlike the traditional approach of casting concrete in a mould.

With the latest technology, a house can be 3D printed in just 24 hours for about half the cost, while construction on the world’s first 3D printed community began in 2019 in Mexico.

The emerging industry is already supporting architectural and engineering innovation, such as a 3D printed office building in Dubai, a nature-mimicking concrete bridge in Madrid and The Netherlands’ sail-shaped “Europe Building”.

The research team in RMIT’s School of Engineering focuses on 3D printing concrete, exploring ways to enhance the finished product through different combinations of printing pattern design, material choices, modelling, design optimisation and reinforcement options.

 

Patterns for printing

The most conventional pattern used in 3D printing is unidirectional, where layers are laid down on top of each other in parallel lines.

The new study published in a special issue of 3D Printing and Additive Manufacturing investigated the effect of different printing patterns on the strength of steel fibre-enhanced concrete.

Previous research by the RMIT team found that including 1-2% steel fibres in the concrete mix reduces defects and porosity, increasing strength. The fibres also help the concrete harden early without deformation, enabling higher structures to be built.

The team tested the impact of printing the concrete in helicoidal patterns (inspired by the internal structure of lobster shells), cross-ply and quasi-isotropic patterns (similar to those used for laminated composite structures and layer-by-layer deposited composites) and standard unidirectional patterns.

 

Supporting complex structures

 

The results showed strength improvement from each of the patterns, compared with unidirectional printing, but Tran said the spiral patterns hold the most promise for supporting complex 3D printed concrete structures.

“As lobster shells are naturally strong and naturally curved, we know this could help us deliver stronger concrete shapes like arches and flowing or twisted structures,” he said.

“This work is in early stages so we need further research to test how the concrete performs on a wider range of parameters, but our initial experimental results show we are on the right track.”

Further studies will be supported through a new large-scale mobile concrete 3D printer recently acquired by RMIT – making it the first research institution in the southern hemisphere to commission a machine of this kind. The 5×5m robotic printer will be used by the team to research the 3D printing of houses, buildings and large structural components.

The team will also use the machine to explore the potential for 3D printing with concrete made with recycled waste materials such as soft plastic aggregate.

The work is connected to a new project with industry partners Replas and SR Engineering, focusing on sound-dampening walls made from post-consumer recycled soft plastics and concrete, which was recently supported with an Australian Government Innovations Connections grant.

 

 

 

 

 

 

 

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3D BOOKSTORE

Contour Crafting’s 3D concrete printing technology. Image via CC Corp.

 

A project carried out by the Tsinghua University’s School of Architecture has successfully constructed a 3D printed concrete bookstore in Shanghai’s Wisdom Bay Innovation Park.

The bookstore is due to open to the public at the end of January, and was printed on-site in three weeks, project lead He Yuting told the Global Times.

The building, which will reportedly be China’s first 3D printed concrete bookstore, is the latest in a string of structures based at the innovation park that have been designed and built using additive manufacturing.

3D printing in Wisdom Bay

Built on the former site of a wool textile mill, the Wisdom Bay Innovation Park has been named Shanghia’s first popular science park. Here, more than 300 companies from across the globe engage in 3D printing, intelligent micro manufacturing, virtual reality (VR), augmented reality (AR), and artificial intelligence (AI) robotics projects. Wisdom Bay is also reportedly home to the world’s only 3D printing museum.

In 2019, a 26.3 meter-long and 3.6 meter-wide concrete bridge, hailed the world’s largest at the time, was completed and installed in the park. The project was also carried out by Tsinghua University, which 3D printed the concrete components in 450 hours.

Constructing the bookstore

The project team used “fiber concrete” as the 3D printing material to construct the bookstore in order to resist compression and earthquake effects. Equipped with an underfloor heating system, the building has a floor space of 30 square meters and is able to accommodate 15 people at any one time.

The team printed the structure in three parts. The main outer round wall was printed in-situ, while the roof and the remaining part of the outer wall were printed separately. Now that the printing of the bookstore has been completed, it will be decorated before opening to the public at the end of January.

A new chapter for concrete 3D printing

Concrete 3D printing is being increasingly utilized within the building and construction sector, in many cases providing a cheaper, faster, and low-waste alternative to conventional construction techniques. Optimizing the concrete printing process has been the subject of several recent and ongoing research projects, as has the development of new concrete compositions suitable for rapid additive manufacturing and innovative printing methods.

The US Governent’s Defense Innovation Unit (DIU) has previously demonstrated the potential military applications of concrete 3D printing in partnership with Texas-based construction firm ICON, while concrete specialists QUIKRETE and Contour Crafting Corporation (CC Corp) have partnered for the automated construction of residential, commercial, and industrial buildings in Los Angeles using CC Corp’s concrete printing technology.

Facilities dedicated to the advancement of concrete 3D printing have also sprung up, including 3D concrete specialist Vertico’s new concrete printing facility in Eindhoven which is designed to accelerate its commercial and architectural building applications. Elsewhere, the American University in Dubai announced plans to establish a scientific research center for 3D printing concrete buildings in collaboration with Dubai-based 3D printing service bureau, 3DVinci Creations.

 

Source: 3D Printing Idustry

 

 

 

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Modular builder CoreHaus establishes first UK manufacturing site

L-R Scott Bibby of CoreHaus; Sarah Slaven of Business Durham; and Cllr Carl Marshall of Durham County Council

Innovative modular housebuilder, CoreHaus, is opening its first UK manufacturing site at a County Durham business park as part of its scale-up plans.

CoreHaus has secured its new 20,000 sq ft unit at Jade Business Park, in Murton near Seaham, and recruited a highly skilled team to start production of its unique modular homes, which have already been successfully trialled in the North East of England.

CoreHaus will now be able to expand production and perform a greater scope of work including the assembly of steel frames that are central to its modular homes. The company’s five-year plan will see CoreHaus producing 1,000 modular homes a year, resulting in more than 100 people working across the business.

Managing director of CoreHaus, Scott Bibby, said: “With such a great facility situated in the heart of the North East and at such a competitive rate, it made perfect sense to set up our manufacturing site at Jade Business Park.

“County Durham has a highly skilled and rich labour market which we have already begun to take advantage of. This has allowed us to employ a diverse, highly competent and experienced team from the surrounding area which will allow best practice from multiple industries to be deployed into our products.

“As a social enterprise the generation of social value is highly important to us. The support from Business Durham and the Council has been fantastic so far, we look forward to strengthening this relationship and building upon it further in the future.”

CoreHaus is a joint-venture company between Newton Aycliffe based Carlton & Co Group, the parent company behind North East based Homes by Carlton, and national social enterprise Fusion21, specialists in public procurement for the built environment based near Liverpool.

CoreHaus homes appear much like any traditional build. They differ to both standard brick-built homes as well as other modular designs because of the way they are constructed and assembled. CoreHaus is a flexible combination of being part modular, with a standard, engineered core, that can be configured to meet customer requirements.

Scott Bibby added: “We have been really pleased with the interest and early demand shown for our innovative product. The concept was successfully piloted with Homes by Carlton at a site in County Durham last summer and we are now looking to work together on other new housing developments across the region.

“We’re also talking to local authorities and housing associations. Several have already told us they love the flexible, high-quality nature of the product. It is quick to build, easy to adapt and has a low-carbon footprint.”

Sarah Slaven, Interim managing director at Business Durham, said: “It’s fantastic that CoreHaus have chosen to open their first UK manufacturing site at Jade Business Park, joining Sumitomo Electric Wiring Systems Europe in the first phase of the park. “

Cllr Carl Marshall, Durham County Council’s cabinet member for economic regeneration, said: “We are delighted to welcome CoreHaus to Jade Business Park.  As the economy continues to feel the impact of Covid-19 it is vital we support economic growth and job creation.  Creating high quality facilities to encourage businesses to move to the county is key to generating new opportunities for County Durham residents.  We look forward to welcoming further businesses to this premier development in the near future.”

 

 

 

 

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