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

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The effects of subframe systems on the overall thermal performance of external rainscreen walls

The world is reaching a critical tipping point with global warming. Every year, climate records are being routinely broken, CO2 levels in the atmosphere rising annually, and sea levels continuously creep up as vast ice sheets are melting and collapsing. In 2019, the UK Government declared a national climate emergency, meaning everybody has to take action against this global threat.

To help protect the planet’s eco-system from being plunged into a whole new state, the thermal performance of buildings will be crucial in the fight against climate change. SFS, building envelope specialists, has developed a whitepaper that explores the effects of rainscreen subframe systems on the overall thermal performance of external walls, the specification process, and unique solutions to reduce heat loss through the building envelope.
The climate change emergency
The biggest problem facing buildings today is the performance gap, where buildings use more energy in their operation than originally predicted by compliance calculations. It’s not uncommon for quoted heat loss and/or energy consumption of a building to be up to ten times greater than forecast.
It’s no surprise that future building standards need to be tighter to bring down such high levels of heat loss and energy consumption. While improvements to Part L of the Building Regulations have been mapped out to the ‘Future Homes Standard’, there is still little focus on achieving the quality assurance that would ultimately avoid the performance gap. At the same time, construction products and techniques must continue to improve to bring operational energy efficiency in line with designed energy efficiency.

Calculating an accurate U-Value
Energy efficiency can only be tackled by understanding the thermal performance of rainscreen walls, where building fabric heat losses are most prevalent as external walls are responsible for 35% total heat loss of a building. Part of that process for understanding how much heat loss a building has is finding out its U-Value.
However, when a U-Value is calculated, it must take into account where insulation is penetrated by the thermal bridges of a rainscreen subframe system. Many materials which bridge the insulation layer have a higher thermal conductivity than the insulation layer, creating higher rates of localised heat loss.

Reducing heat loss through rainscreen subframes
The careful selection, specification and installation of an optimal thermally efficient subframe system, supported by the appropriate thermal modelling is crucial.
Part of that specification is choosing the right rainscreen subframe system. Developments in recent years means that newer systems now have lower thermal conductivity, allowing contractors to choose a solution to lower the loss of heat.
The solution
The relationship between the design and realisation of a building is key for greener building projects. Only by having the right specification for your rainscreen subframe can you guarantee that your external wall construction performs as well as intended.

So, what is the solution? SFS has been working on rainscreen subframe solutions that provide key energy saving contributions to any project featuring cladding.

To find out more how the SFS’ NVELOPE® system can be optimised to your project to achieve the thinnest build-up and make your building greener, CLICK HERE to download the whitepaper.

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ASSURED FIXING SOLUTION

ETA-approved EJOT Iso-Corner provides assured fixing solution for externally insulated walls

EJOT has secured ETA (European Technical Assessment) approval for its Iso-Corner load-bearing bracket, an engineered fastening element for medium to heavy weight building elements – planned or unplanned – in ETICS and other external wall insulation applications.

The newly awarded ETA confirms the engineered value of EJOT Iso-Corner which is moulded from high density polyurethane foam and can be easily cut on site with an electric saw to sit flush with the external insulation face. This combination of structural strength and adaptability provides a dependable supporting bracket option offering a cantilever arm to length of between 80mm and 300mm.
It is ideally suited to specifiers and installers who need to attach building elements to a façade that is to be treated with an ETICS – external thermal insulation composite systems – or other external wall insulation solution. These could include elements such as railings and Juliet balconies, which require a secure attachment to the load-bearing external wall, the substrate.
Consider the make-up of an external wall insulation system. The insulation is typically attached to the wall structure, treated with coatings and mesh, and finished in the chosen render, brick-slips or other external treatment. The main depth of the system is the insulation board, and whilst this should generally be very securely fixed to the building substrate, it will not have the necessary structural strength to allow for load bearing attachments.
Any attempt to achieve a secure fix by driving through to the original building substrate could compromise the thermal insulation level. Unless a fixing is used that incorporates insulating materials as part of its design, the thermal barrier will be broken, and cold bridging will result. This is one of the criteria of PAS 2035, where it needs to be demonstrated that any cold bridging effects have been designed out of the chosen energy efficiency measure.
Iso-Corner is part of a range of ETICS mounting elements from EJOT designed to achieve safe, secure and long-term fastening solutions in refurbishment projects, including:

•  Iso-Spiral Anchor, a spiral-shaped plastic assembly anchor complete with sealing washer and integrated threaded sleeve which provides a fastening solution for lightweight elements in ETICS facades, such as house numbers and external lights.
•  Iso-Dart – a fastening system comprising of a façade anchor with plastic installation bush, complete with sealing washer, which accepts common coarse threaded screws for securely attaching light to medium loads.
•  Iso-Bloc – an easy-to-cut block moulded from high density EPS, which is particularly suitable as a backing to allow for thermal bridge-free attachments in ETICS applications.

 

As a global leader in construction fastening solutions, the EJOT UK team offers a wealth of technical support and specialist guidance to specifiers and installers to ensure they achieve the right result when mounting to ETICS facades.
For technical support and to find out more about the range of innovative EJOT fastener solutions visit the website, call 01977 687040 – or contact Mark Newell, Sales Engineer for ETICS fastening products at EJOT UK: m.newell@ejot.co.uk

www.ejot.co.uk

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concrete sandwich panels for multi-storey’s

Thermally broken non-combustible concrete sandwich panels

#constructionindustry #architects #localauthorities #contractors #developers #innovation #buildingtechnology #mmc #thermlpanels #concrete #non-combustible @csm_uk_ltd

 

CSM-UK continue to research, develop and supply solutions for thermally broken precast sandwich panels using Thermomass® bespoke high-capacity connectors and non-combustible insulation.

For over 20 years, CSM-UK has supplied Thermomass® connectors and thermal insulation solutions for a wide range of building types including schools, hospitals, offices, custodial and industrial buildings. In recent years, we have seen a rise in demand for multi-storey residential projects where the requirement for enhanced U-values and non-combustible insulation materials has greatly increased insulation thicknesses. This has placed a greater demand on connector capacities especially when delivering articulated facades with deep reveals and facing materials such as brick, terracotta, natural stone and architectural concrete.

Non-combustible insulation used with the Thermomass® system typically varies in thickness from 100mm to 300mm for U-values of 0.34W/m2K to 0.12W/m2K. The two solutions available are: –

•  TROK® (European Fire Classification A1) is the solution for a cost-effective non-combustible core in concrete sandwich walls. It is a mineral wool insulation, exclusively made for CSM-UK by the UK’s leading mineral wool manufacturers for use with the Thermomass® System.
•  OAMGLAS® W+F (European Fire Classification A1) is a leader in cellular glass insulation. It is a high-performance, non-combustible, light weight, rigid and durable insulation composed of millions of completely sealed glass cells. It is the premium insulation solution for use with the Thermomass® System
With these insulation solutions, you can use Thermomass® bespoke Star connectors. These typically vary in length from 200mm to 400mm, which includes an additional 50mm each end for the embedment into the internal and external concrete layers. For even greater loads to the external layer, the large capacity X connectors can be employed.
The multi-storey residential buildings we are showcasing have different insulation thicknesses and façade aesthetics with differing brick types and architectural concrete finishes.
•  St. Martins Place, Birmingham, the main tower is 17 storeys, and will feature a total of 228 residential apartments, using Creagh Concrete Products Ltd Rapidres solution incorporating architectural concrete and brick finish sandwich panels. Creagh Concrete Products Ltd have BBA Certification for their Rapidres solution, an insulated precast concrete sandwich wall system.
•  The Lansdowne, Hagley Road, Birmingham, is an 18 storey building housing 206 modern apartments. The external walls are 410mm thick and of a ‘sandwich’ construction, with the outer 80mm thick facade consisting of a detailed buff brick design. The insulation layer sits between the inner and outer concrete faces. The facade panels have been manufactured by FP McCann Ltd along with the other crosswall elements.
•  3 St. Peters Square Manchester, is a 20 storey hotel and apart-hotel with triple punched window facade sandwich panels with a formliner finish within a crosswall construction solution manufactured off-site by FP McCann.
•  Sutton Court Road London, is a ‘build to rent’ residential development of 165 flats in a part 10, 11, 20 and 21 storey building. Creagh Concrete Products Ltd manufactured brick-faced and architectural concrete sandwich panels

 

To see additional projects, see our Twitter page at @csm_uk_ltd. We are up to 2010 in our retrospective of 21 years of CSM-UK supplied solutions.
CSM-UK offer a service providing U-value calculations and condensation risk analysis to assist in the design of sandwich panel solutions. For more information, please call +44 (0)1246 853828 or email sales@csm-uk.co.uk or visit our website for our latest brochure.

www.csm-uk.co.uk

 

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MASONRY FOR THE FUTURE

The design of the blocks is such that they require no mortar or adhesive

#constructionindustry #architects #localauthorities #contractors #developers #buildingtechnology #mmc #clayblocksystem #thinjointadhesive #structural @evolvedsupplys

The JUWO Evolved SmartWall™ Building System – thin joint masonry for the future

The Evolved Supplies JUWO Evolved SmartWall™ building system consists of a monolithic clay block system which gives a modern method of construction with thin joint adhesive technology.

The design of the blocks is such that they require no mortar or adhesive on the interlocking vertical joints. The fired, aerated clay blocks are manufactured to a tolerance of 1mm in height and come as a complete system that includes lintels, corner and shaped blocks, insulated mortar, adhesive and applicators.

These structural blocks have been used for many years across Europe and are suitable for load bearing and non-load bearing walls, for external & internal applications. They have full LABC approval and comply to BS EN 771-1 and carry the CE mark with an A1 fire rating, making them the ideal building system for low and high rise developments as well as for the self-builder.

SmartWall™ Benefits
• Excellent Thermal Performance.
•  Meets & Exceeds Building Regulation requirements.
• Quick Construction Time.
• Single solid wall construction.
• Modern Method of Construction
• Thin bed mortar technology
• Complete Building System.
• 85% less moisture in construction
• Completely Vapour permeable
• External Insulation to give that ‘tea cosy’ effect

Clay is possibly one of the most sustainable materials used in construction. It is a natural material that it easy to work with and provides a comfortable living environment.

SmartWall™ explained
The Smart Wall system delivers a much faster build time. The thin joint adhesive allows you to continually work without being restricted to the number of lifts in a day, on average, up to 40sqm can be achieved per person per day.

SmartWall™, being a monolithic building system, means that you have just one skin for your building structure, no cavity, therefore minimising areas for complicated detailing and areas for insulation to be missed.

 

 

With standard masonry systems, drying out can be problematic in the UK climate. The adhesive layer helps to reduce moisture in the building by over 85%, this, coupled with the faster build time, means that your building can be roofed and weathertight in a much shorter period of time.

The adhesive mortar comes as part of the SmartWall™ system & has been designed for use in temperatures from 0°C, so winter working is not a problem.

Efficiencies & Performance
The SmartWall™ building system has a superior thermal performance compared to other similar products, making it easy to achieve Building Regulation requirements without the need for additional wall insulation or increase in foundation size.

The thermal performance of SmartWall™, together with the density of the blocks, provide excellent thermal mass. Too many modern homes face the risk of summer overheating. The SmartWall™ system provides warmth in Winter and comfort in Summer. The clay will also regulate humidity levels within the home and it is recommended that a mineral plaster finish is applied directly to the blocks to maximise this performance.

Air tightness is achieved by applying a ‘parging’ coat of wet plaster to the inner face of the blocks. This is a standard method of achieving good air tightness and recommended by the Passivhaus Institute.

By applying a vapour open render finish to the external surface of the blocks, coupled with the mineral plaster inner finish, SmartWall™ provides a complete vapour open system. Thermal modelling shows that interstitial condensation will not form within the construction.

The SmartWall™ system provides a thermal bridge free method of construction without the need for complicated detailing.

Being manufactured from clay, the SmartWall™ blocks have an inherently good fire performance and have a rating of A1 reaction to fire.

The SmartWall™ System has been developed for anyone to use and Evolved Supplies can provide ‘on-site’ training, if requested.

For more information, visit the website or call 01691 707100.

www.evolvedsupplies.co.uk

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WRAPTHERM GETS FULL BUILDING REGULATIONS APPROVAL

High-performance membrane composite, self-adhesive specifically for refurbishment

#constructionindustry #sustainable #architects #localauthorities #contractors #developers #buildingtechnology #mmc #thermalairtightness @proctorgroup

Wraptherm has been awarded certification from both LABC and LABSS confirming that the product meets Building Regulation approval in England, Wales and Scotland. Wraptherm will improve airtightness levels whilst at the same time addresses the need to reduce thermal bridging in refurbishment projects.

The high-performance membrane composite is self-adhesive and is specifically developed to be applied during the refurbishment of existing buildings where there is a requirement to enhance the thermal and airtightness performance of the building. Wraptherm can also be used in new build construction where the reduction of thermal bridging and improving the airtightness is required, e.g. around steel lintels or around concrete columns.

 

 

Wraptherm consists of a 10mm Spacetherm aerogel insulation blanket bonded to the face of Wraptite, the industry recognised vapour permeable, self-adhesive airtight membrane.

When applied to the internal face of the existing façade, Wraptherm provides a vapour permeable yet airtight layer, fully self-adhered to the substrate beneath with the added benefit of a 10mm thick layer of high-performance Spacetherm insulation blanket.

Over this airtight/thermal composite framing can then be installed with the added benefit of a reduction in thermal bridging due to the Spacetherm layer. Where required, additional thermal insulation can be included within the frame to meet the specific U-value requirements of the project.

The offset nature of the Wraptite component allows for a completely robust sealing of all of the joints within the panel thereby ensuring the continuity, integrity and robustness of the airtight layer.

 

www.proctorgroup.com

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Kingspan TEK Gets Sporty at New Pavilion

The Kingspan TEK Building System of structural insulated panels (SIPs) has provided the bespoke, thermally efficient shell for a minimalist pavilion at Eton College’s Willowbrook Outdoor Sports Centre.

The stunning single-storey building, designed by Lewandowski Architects, sits at the centre of the site and provides a range of facilities including changing rooms, toilets and a kitchen along with a roof-top viewing platform. Feltham Construction managed work on the project which included the demolition of the building’s outdated predecessor. Wood was a key part of the material palette with charred timber fitted for the outer cladding and birch-ply boards fitted internally. This approach extended to the structure, with Bentley SIP Systems using the Kingspan TEK Building System for the walls of the structural shell.

Kingspan TEK Building System is formed from SIPs with a high performance, rigid insulation core autohesively bonded between two OSB/3 facings. 142mm thick Kingspan TEK panels were selected for the walls of the pavilion. As Kingspan TEK Delivery Partners, Bentley SIP Systems oversaw the design and factory cutting of the panels before delivering them to site.

David Bentley from Bentley SIP Systems discussed the project:

“The Kingspan TEK Building System was specified by Lewandowski Architects at the pre-tender stage and we worked with them from that point to the erection of the building shell. The System was chosen both because of its excellent insulation properties and because it could facilitate a fast-track construction programme. As we pre-cut each panel to the project’s specific requirements, we were easily able to incorporate features such as the structural steel which supports the retractable glazing to the front of the building.”

 

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The Kingspan TEK Building System’s unique jointing system ensures insulation continuity between the panels, helping to minimise repeating thermal bridges. In combination with the OSB/3 facing, this jointing arrangement also facilitates the creation of highly airtight buildings. This should help to reduce the long-term heating requirements for the project and provide a warm, comfortable environment for athletes and spectators.

Bentley SIP Systems’ operatives were able to rapidly erect the SIPs with a dry installation programme. The precision factory design eliminated the need for offsite alterations and waste whilst the OSB/3 facing provided an ideal substrate for the external and internal timber cladding.

For further information, please contact:

 

Tel: +44 (0) 1544 387 384

Fax: +44 (0) 1544 387 484

e.mail: literature@kingspantek.co.uk

Website: www.kingspantek.co.uk

www.twitter.com/KingspanIns_UK

www.linkedin.com/company/kingspan-insulation-uk

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How Pipe Insulation Can Support Thermal Comfort

By Carl Davison Technical Services Manager at Kingspan Industrial Insulation.

Thermal comfort has become the focus of increasing attention in recent years as designers and project teams look to create a healthier built environment. Whilst the enhanced thermal performance and airtightness provided by some offsite envelope solutions can help to make indoor conditions more easily controllable, careful attention must also be paid to potential heat sources within a space which can lead to overheating. Research from AECOM has now shown that pipe insulation specification can have a major bearing on how easily properties overheat, as well as on their overall energy demand.

Requirements
The minimum insulation requirements when specifying hot water and heating systems are contained within the Domestic and Non-domestic Building Service Compliance Guides1. For optimal system efficiency, however, the Energy Technology List (ETL) recommends a higher performance pipe insulation specification based on NES Y50 Enhanced levels.
A wide range of pipe insulation options are now available and a key differentiator between these is their thermal conductivity. Insulation materials with a lower thermal conductivity are more effective at preventing heat transfer through conduction, meaning a reduced thickness can be used to achieve the desired level of insulating performance. Premium phenolic pipe insulants are amongst the most thermally efficient options, with a 25-year aged thermal conductivity as low as 0.025 W/m·K (at 10°C mean), and are available with phenolic insulation pipe supports to further minimise heat losses.

Research
To investigate how these different specifications can affect overheating and system performance, AECOM carried out a detailed evaluation using IES dynamic thermal modelling. The research assessed the performance of three insulation systems on LTHW (Low Temperature Hot Water) and DHW (Domestic Hot Water) pipework, within a multi-unit residential extra-care building with a constant circulation of hot water:
1   Man Made Mineral Fibre (MMMF) Pipe insulation specified to BS 5422: 2009 with rubber lined pipe support brackets.
2  Phenolic pipe insulation specified to minimum standards within BS 5422: 2009 with phenolic insulation pipe support inserts.
3  Phenolic pipe insulation to the enhanced
ETL specification with phenolic insulation pipe support inserts.
The study also considered the use of extraction fans to dissipate heat.

Results
To evaluate the impact of each specification on overheating, AECOM calculated the percentage of hours with a dry resultant temperature of greater than 25°C2 and 28°C3.
The results showed that, when compared with the MMMF system, the BS 5422 phenolic specification provided a reduction of up to 15% in overheating hours at a room temperature greater than 28°C, and up to 9% at a room temperature greater than 25°C.  The ETL specification offered significant further benefits with falls of up to 32% in overheating hours greater than 28°C, and 25% in overheating hours over 25°C.
In some scenarios, the modelling showed that rooms with the MMMF specification would have experienced over 100 additional hours at temperatures above 28ºC when compared to the ETL specification.
These reductions also produced considerable energy cost savings. The projected average energy cost of the MMMF specification was calculated at £3,973, rising to £4,105 when the impact of additional extraction fans was considered. The BS 5422 phenolic specification achieved annual savings of £431 or £463 depending on whether the impact of extraction fans was taken into account. With the ETL phenolic specification even greater savings of £1,252 and £1,384 could be achieved.
Finally, the study showed that when the extract fans were considered, the ETL specification would have an immediate payback.

In control
The move towards a healthier, more energy efficient built environment requires project teams to think more holistically about how all of the elements will interact. As the AECOM research shows, by paying close attention to areas such as pipe insulation specification, it is possible to achieve considerable reductions in both energy demand and overheating hours.

www.kingspanindustrialinsulation.com

 

1  This expands on the specifications within BS 5422: 2009 (Method for specifying thermal insulating materials for pipes, tanks, vessels, ductwork and equipment operating within the temperature range -40°C to +700°C)
2  The recommended acceptable indoor design operative temperature within CIBSE Guide A 2006
3 The preferred maximum temperature for thermal comfort

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ICF – Insulation Comes First

Now that the glamour of being photographed beside the latest renewable technology of wind turbines and solar farms has worn off, the principle of Fabric First is being recognised as a more immediate and reliable process of improving energy efficiency in buildings.   

Even without the subsidies and grants awarded for generating energy, the benefits and long term economy of improving the performance of building fabric has at last been recognised as more significant in the equation of balancing our environmental impact.
FABRIC FIRST has become the strapline for sustainable construction.  After all, if you build a decent stable with a well fitted door, the horse (ie. energy) wouldn’t be able to bolt and, given the improved comfort levels in the building, probably wouldn’t want to anyway!
Retaining energy in the building reduces energy demand and the detrimental effect of lost energy on the ice caps.   Reducing energy demand reduces energy costs and environmental impact.   The more passive buildings are in terms of energy needs, the more the environmental impact is reduced – permanently.
FABRIC FIRST – Insulation is the key ingredient
By improving the performance of building fabric – thermal insulation, air tightness, elimination of cold bridges – energy demand is reduced.   ICF (Insulating Concrete Formwork) building systems do just that, as a complete formwork system to contain the concrete structure they are also a complete insulation system to contain the energy.   ICF (Insulation Comes First) is a primary means of reducing energy demand in buildings, and the Wallform ICF system has been designed and detailed to maximise the efficiency of the building envelope.

 

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The simple logic of ICF construction enhances the overall performance of the building – insulation on the face of the wall where it is most effective, complete insulation with good airtightness and no thermal bridging.   With nothing to rot, corrode or deteriorate over time, a Wallform structure will last significantly longer than other forms of construction.
Although build costs are increasingly competitive as ICF becomes more popular, long life expectancy places Wallform ICF ahead of alternative building methods in terms of both Total Life Costing and carbon footprint.
AND – should the building reach the end of its useful life, the materials can be recycled into a new generation of building materials.

FABRIC FIRST – PRODUCTIVITY NEXT
While ICF construction is a practical route to raising performance standards, UK construction still has to overcome the problem of productivity which has not improved in recent years.   Efforts to upgrade the performance of traditional building methods have complicated the building process and constrained output.
Wallform ICF, on the other hand, actually simplifies the building process, speeding up the rate of build at the same time as producing a strong structure which is fully insulated and airtight in its basic format.   Other than use of a concrete pump to place the concrete, the building process does not require any specialist tools or equipment to achieve high rates of productivity.
Quality of construction is also improved as the materials’ functions overlap – no leakage of concrete through the formwork means no leakage of energy as there are no gaps in the insulation.   Similarly as the structure is built, the concrete seals it with a high level of airtightness.   First fix services are then recessed easily into the insulation substrate, with no effect on airtightness.
The practical building technique means that upskilling the existing workforce is a relatively smooth process of transition.   The introduction of ICF methods causes minimal disruption and is an opportunity for the existing workforce to raise levels of output in the process of adopting a Modern Method of Construction.    Site performance is improved and the processes of procurement and management made easier as a consequence of a simpler building method.

www.becowallform.co.uk

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Simplifying airtightness in modular & offsite construction

The A. Proctor Group has, for over 50 years, been serving the construction industry with an extensive portfolio of technically advanced thermal insulation, specialist membranes and vapour control layers, providing an extensive range of superior high-performance products suitable for modular and off-site construction.

 

The basis of best practice in modular construction comes from an understanding of the relevant building regulations and a holistic approach to the building design. In doing so we consider six core aspects in the process related to the balance of Heat Air Moisture Management (HAMM):

  • Building
  • Weather
  • Occupants
  • Heat
  • Air
  • Moisture

Building

The first area to consider is the type of building fabric involved. Concrete, steel and timber-based buildings all respond differently to moisture and contain different amounts of construction moisture which must be allowed to dry out. For example, buildings with a lot of in-situ concrete can take several years to fully dry out, this excess moisture load must be accounted for at the design stage.

Weather

Construction moisture can also come from the weather, and this must also be taken into account along with the weather conditions the building will be subjected to once completed. Being weather tight earlier in the construction process and generally being composed of drier materials, offsite construction has an important hygrothermal advantage.

Occupants

By reducing the initial moisture loading on the building fabric, the design can be more precisely tailored to manage moisture associated with the occupants of the building and the uses the building will be put to, leading in turn to a more efficient fabric envelope and building system.

The influences of these three aspects can then be assessed in terms of the heat, air and moisture movement within the building. This takes into account the heating of the building, as well as the air leakage effects and response of the building fabric to the absorption and desorption of moisture. Factors such as the position and performance of the fabric insulation can also be considered.

 

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To ensure our design adequately manages these complex interactions, we undertake a hygrothermal analysis of the building fabric using software called WUFI. This breaks the building elements into individual layers and calculates the temperatures, moisture flow and degree of water storage at any point in the building fabric. This detailed analysis allows us to consider solutions that may mean that the internal vapour control layer can be removed altogether without creating a condensation risk.

This is made possible by the use of an external vapour permeable air barrier membrane. The Wraptite® membrane self adheres to the external face of the sheathing and provides a robust airtight layer without compromising moisture movement through the wall assembly.

By removing the vapour control in favour of an external air leakage solution we remove the associated material and installation costs, and more importantly, we remove the need to seal all the service penetrations, meaning we have a more reliable air barrier and can reduce the air leakage rates applied at the design stage.

In modular systems, incorporating an external air barrier is simple and brings several benefits over traditional mechanically fixed membranes.

Wraptite membrane can be applied to the panels in any orientation, and being self-adhered requires no mechanical fixings. This adhesion reduces the potential for membrane damage both during the module assembly process and while in transit to the site.

The panels are then assembled and the joints taped using Wraptite Tape, ensuring no adhesion issues or tape compatibility problems, and the panel assembly is now resistant to air leakage. The wall, roof and floor panels can then be assembled into modules, and Wraptite split-liner tape used to complete the airtight seal between adjacent assemblies. The completed modules can then be transported to site with full protection from the elements.

www.proctorgroup.com

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