Winter 2004/2005

Off-site prefabrication
Design matters
Innovation in production methods and
significant investment in labour and plant
resources enable architectural precast
Chairman of the ACA, Stephen Maddalena considers the concrete panels to be provided in an
advantages of precast cladding increasing range of finishes and facings,

A
shapes and sizes to suit the requirements of
lthough topical in consequence of the Latham-inspired initiatives and individual projects.
increasingly recognised as being a merited solution to the challenge of providing Finishes and facings
optimum value, off-site prefabrication is not a new concept. Architectural
precast concrete panels have been produced off-site for many decades and are A comprehensive range of cladding finishes
increasingly being specified to clad a wide range of new buildings including commercial and is available ranging from lightly textured
civic office schemes, residential, retail and leisure developments as well as hospitals and reconstructed stone and polished concrete
schools. Despite this trend, there are many building projects that fail to benefit because finishes to coarser washed exposed aggregate
the advantages of precast cladding construction are not fully considered early enough. surfaces. Aggregates and cements can be
selected to suit colour preferences. Precasting
The direct and incidental advantages of to enhancing quality and safety, to improving
precast cladding construction are many and efficiency and productivity and to providing
varied. Importantly, they valuably contribute programme and price certainty.
continued on page 2

Rising high at Discovery Dock

D
esigned by Chantrey Davis
and Shepherd Design
and built by Shepherd
Construction, the Discovery
Dock development in Canary Wharf, is
predominantly clad in reconstructed stone
panels supplied and erected by Techrete
(UK) Ltd.
The largely residential development,
comprises three blocks; 14 storey, 16 storey
and the 25 storey tower. The panels are in
the main double-punched window units,
and were delivered to the site, following
the installation of the windows at Techrete’s
factory by Parry Bowen, the curtain wall
subcontractor. Typically 6m x 3m and
weighing up to 9 tonnes the panels were
produced with cut-outs to accommodate
the cantilever support beams for the steel
balconies.
Although there was very good panel
repetition, it was necessary to manufacture
several ‘challenging’ shapes, which in some
cases resulted in the adoption of a two-stage
casting process.
With such expansive areas of cladding
it was important to minimise panel-
to-panel colour variation and a new
mix was developed by Techrete to
provide as much colour stability as can
be achieved, using natural materials
The panels were fixed to the
reinforced concrete frame, where
the load was transmitted via integral
corbels on the rear of the panels
adjacent to the columns.
The restraint fixing was via channels
typically cast into the underside of
the post-tensioned floor slab, where
accurate positioning of cast-in fixings
has a substantial bearing on the
economic and smooth running of
the cladding system. Insulation and
horizontal fire stopping was also
included within the precast concrete
cladding package.
continued on page 3
Off-site prefabrication
continued from page 1
effectively allows the pre-assembly of natural
stone, granite, brick and terracotta tile facings
with a reinforced concrete backing, a single
panel perhaps incorporating 100+ facing
stones or 1000+ bricks.
Natural stones and granites are used
more economically than with traditional
construction methods as they can be
produced in thinner sections. Panels may
include a mix of finishes and facings that
would otherwise demand separate trades.
Shapes and sizes
Fresh concrete is an extremely mouldable
material allowing complex shapes to be
formed. Panels can economically incorporate
cill, coping, soffit, window reveal and special
sections, especially where repetitive. Large
panels avoid the need for secondary structure
for their vertical support and lateral restraint.
Grid-width units can reduce mid-span
loadings onto the structural slab edge.
Panel sizes are usually limited by site craneage
or transport constraints. Limitations may be
overcome by using low-loader trailers that
allow storey-height panels to be delivered
vertically. Reduced wall thicknesses with
precast cladding panels can increase net
lettable floor area.
Quality matters
Panels are produced by skilled
craftsmen, motivated by long-
term employment prospects, in a
purpose-built factory environment
using specialist equipment. Each
stage of manufacture is subject
to inspection in accordance with
an independently certified quality
system, and finish and dimensional
accuracy are checked before
delivery.
Sustainability matters
Precast panel construction produces negligible
waste, just enough concrete being batched
to fill available moulds. And at the end of the
economic life of a building, the precast panels
may be refurbished for re-use or crushed for
recycling.
Functional matters
Precast concrete cladding produced in
accordance with BS 8297:2000 has a life
expectancy of 60+ years and is generally
maintenance-free. Dense concrete is air- areas of the frame to be rapidly enclosed
and water-tight, giving superior weathering to give an early start to weather-sensitive
performance and corrosion resistance. Joints following trades. Window apertures within
between panels are usually filled with sealant.
the panels can be framed, glazed and sealed
The thermal mass of concrete serves to reduce
before delivery.
peak heating and cooling loads. Insulation can
readily be incorporated either as a lining to the In addition to issues of quality and practicality,
internal face of a panel or as a core between each of the above points correspondingly
two concrete layers, achieving U- contributes financial advantages. Off-
value requirements of 0.35W/m2K site prefabrication and increased on-site
and better. In addition, concrete is productivity, especially using the largest units
an inherent sound insulator, non- that are practical to deliver and handle at site,
combustible and fire-resistant. facilitate optimum value. Similarly, decreasing
Construction matters the dependence on site-based activities
Precast cladding panels are erected helps stabilise the total construction cost and
on site by specialist teams trained shortens construction periods, at the same
in safe handling and fixing, typically time reducing financing costs. However, it
without the need for an external should be recognised that all these advantages
scaffold. Panels are delivered on can only be attained by early involvement of
a just-in-time basis, allowing large the specialist precaster.

TECHRETE INVESTS IN UK PLANT

T
echrete, a leading manufacturer
of architectural precast
concrete in Ireland and the
UK, has invested €5 million
in an extension to its UK works at Brigg,
making it one of the most modern factories
in Europe. This reflects the company’s
increasing volume of business in the UK.
Plant director John Stothard commented,
“This expansion will create more space for
conventional production, as well as housing
a new robotic plant to streamline the
production of architectural concrete.”
A key feature will be a carousel system in which
steel moulds will travel to the operative rather
than visa versa. The aim is that all curing and
finishing will be contained within the building,
thus creating a better working environment
and a controlled curing regime for the panels.
According to Stothard, “The advantages
are that each product will be finished in a
controlled environment regardless of the
season and external areas will only be used
for storage of completed units. Achieving this
is quite a challenge as much of the equipment
is bespoke and must be adapted for the
special needs of architectural concrete.”
The new building and offices are constructed of
Techrete’s precast concrete sandwich panels,
which provide a complete wall solution.
Combined natural and reconstructed Portland
stone for Belgrave House facade
The project also benefited from maximising
the use of precast and specification of a
large-panel scheme. This enabled rapid
construction and the early enclosure of a
weatherproof envelope, allowing follow-on
trades to start sooner.
Client: Belgrave House Development Ltd &
JER Victoria Ltd
Contractor: Sir Robert McAlpine Ltd
Architect: Squire and Partners
Engineer: Whitby Bird and Partners

Award for Trent

The Experian Data Centre in Nottingham
is the winner of the Building category
in this year’s Concrete Society Awards

T
rent Concrete recently
completed its £2.3m
cladding contract at Belgrave
House, a high-profile office
development at the rear of Victoria Station
on Buckingham Palace Road in London.
The contract was awarded following a
two-stage tender process, with Trent’s
previous successful cladding work with
contractors Sir Robert McAlpine (on the
new Bull Ring development in Birmingham)
proving influential.
Trent designed, manufactured and erected
350 units in total. In the main these were
two-storey mullions, 7.5m high, with a facing
of deeply profiled natural Portland stone, and
8.5m long spandrels with projecting Portland
stone sills. Trent was also responsible for
600m2 of handset in-situ Portland stone
cladding. In addition, 1000m2 of matching
reconstructed stone cladding for the service
core and plant room were produced.
This combined natural and reconstructed
stone approach provides a high-quality, cost-
effective solution. Natural stone is used on
the main elevations, whilst reconstructed
stone is used elsewhere and provides an
extremely good imitation of the natural stone
in both colour and texture.
held at the London Marriott Hotel on
4 November. The judge’s commented
“Viewed from the front, the building is
striking: indeed its innovation is in the
appearance. Low rise, precast, pigmented
concrete units have been differentially
etched and are of various lengths to
provide a bomb-resistant screen with
unspectacular but effective windows. The
building is unobtrusive and entirely in
harmony with the surroundings.”
Architect for the project was Sheppard
Robson, main contractor Bowmer &
Kirkland Ltd and the precaster Trent
Concrete Ltd.

Rising high at Discovery Dock

continued from page 1

Erection of the 880 or so panels was completed

in approximately seven months, with a month
or so ‘overlap’ as the double mastic pointing was
applied by a youthful but very professional team
of abseilers. Serious consideration has to be
given to wind conditions at Canary Wharf, when
formulating a programme for this type of system;
crane down-time of 40% is not uncommon.
A further challenge to be addressed was
negotiating the cantilever formwork at roof
levels, this was achieved by using a ‘C’ hook
which circumnavigated the obstruction and
resulted in a smoother operation than had been
envisaged.
An Innovative Solution
A
rup Associates’ design of this
new office block for British
Land incorporates an innovative
solution to the construction of
its facade, albeit founded on the traditional
principle of a load-bearing structure.
The facade includes storey-height panels of
Bavarian limestone and reconstructed stone
finished precast concrete spandrel units, both
acting as structural elements.
The natural stone panels, which serve as
the perimeter columns, were provided by
Stone Cladding International. Each column
was constructed as a set of five solid blocks of
stone that were pre-tensioned with steel tie-
bars to prevent their splaying under load.
The precast concrete spandrel units at each
floor level provide the connection between
the stone panels and the steel beams that tie
the facade back to the main structure. The
precast spandrels were manufactured and
the appearance of the natural stone. Each fixing positions on both the stone panel and
delivered by The Marble Mosaic Co Ltd,
spandrel unit required a number of stainless steel beam.
typically as 6m-long units. The concrete
mix and surface finish specifications for their steel boxes to be cast-in with exceptional The stone panels and precast spandrels were
manufacture were developed to match accuracy to suit the irregular locations of the erected by William Hare for Bovis Lend Lease.

Welcome to new member

W
ith over twenty years experience of providing
architectural concrete solutions on the Continent,
Belgium based Decomo, entered the UK market
in 1998.
Offering complete design, supply and installation packages, the
company’s ethos is based on providing client satisfaction and it is
always striving to give that “little bit extra” in order to enhance both its
product and service.

With such prestigious projects as the European Parliament Building in
Strasbourg and the Hilton Hotel in Paris to its credit, it was not long
before the company’s expertise and flair became recognised by many
leading UK architects and contractors.
An impressive portfolio of completed projects, this side of the Channel,
built up over the last six years, is something Decomo UK Ltd is now
rightly proud of. Amongst these are the Guinness Headquarters in
London, the Fenwick Store in Canterbury and the Royal Academy of
Music in London.
Currently, three major projects are being undertaken, at Wembley
Park Station, Chesham House and the University College, London.
This is evident, not only in the extensive range of finishes and colours
available, but also from the substantial investments made in production
facilities, equipment and people.
This year, alone, a new finishing building, covering an additional
3500m2 has been opened in Mouscron, Belgium, where all production
is undertaken. A new office building and showroom is also planned for
construction next year.
In the UK, offices have recently been opened in London, where Paul
Desmet has been joined by Andrew Tyrrell, formerly with Histon
Concrete Products Ltd, to provide closer client support as the
company realises its targets for continued growth in a market which it
believes holds much potential.

Architectural Cladding Association 60 Charles Street, Leicester LE1 1FB.

Tel: 0116 253 6161 Fax: 0116 251 4568 Website: www.britishprecast.org/aca

Member Companies
Decomo UK Ltd, 180-186 Kings Cross Road, London, WC1X 9DE. Tel: 0207 689 8058. Contact: Paul Desmet.
Redland Precast Concrete Products Ltd, 15/F Kai Seng Commercial Centre, 4-6 Han Kow Road, Tsimshatsui, Kowloon, Hong Kong. A product association of British Precast
Tel: 00852 2590 0328. Contact: Trevor Gregory.
Techrete (UK) Ltd, Warren Court, Feldspar Close, Warren Park Way, Enderby, Leics, LE4 5SD. Tel: 0116 275 0785. Contact: David Kennell.
The Marble Mosaic Company Ltd, Winterstoke Road, Weston-super-Mare, BS23 3YE. Tel: 01934 419941. Contact: Stephen Maddalena.
Trent Concrete Ltd, Colwick, Nottingham, NG4 2BG. Tel: 0115 987 9747. Contact: David Walker.