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Offsite construction

Implementation of Precast Sandwich Brickwork

Although construction with precast sandwich panels with full size brickwork is a new approach in the UK, Ballymore selected this method to construct the Phase 1 residential tower blocks at their London City Island development. Ranging from 11 storeys to 19 storeys across the four blocks the system has a completely precast concrete structure from level 1, including floors, internal…


Prefabricated Frames Offsite

Utilising a BIM Model and clash detection, it was enabled for designers to design a frame which holds all the mechanical pipework and associated bracketry to be manufactured at low level and in factory conditions. This then allowed for frames to be delivered to site and be installed at high level using mechanical aids, which will prevent musculoskeletal injuries due…


Hybrid Greener RC Frame Choice

On this project the site boundary is the building boundary. To complicate building construction further two elevations, south and west, abut immediately to existing buildings. At a very early stage of the tender the contractor decided to change the designed 10 storey in-situ RC frame to a hybrid concrete frame. By changing all the vertical in-situ RC structural support elements…


Off Site Prefabricated Reinforcement

On this project they have designed and fabricated off site reinforcement sections for the super flat specialised concrete ground floor slabs of a warehouse. This system consists of a prefabricated roll out bottom matt of reinforcement along with prefabricated top matt sections complete with u-bars around the edges and highchairs attached ready to be installed onto the roll out bottom…


BAMTEC Reinforcement Technology

BAMTEC Reinforcement technology has been implemented on this project for use on superstructure slabs. This is an easy to roll carpet reinforcement with no assembly on site as it is fully prefabricated off site using automated production technology. Using this method had an increase in productivity on site by 50% on steel reinforcement and an approximate 10% savings in tonnage…


Precast Floor ‘U-Slab’

An opportunity arose to demonstrate a bespoke integration of structure and MEP services during the development of this project. After a number of test  assemblies the project team settled on a method where the MEP module was married to the underside of a precast floor slab. Entitled the ‘U-Slab’ due to it’s shape, this method of construction has delivered numerous…


Pre Serviced Walls

On this project they are using pre serviced walls across several of the floors. These are walls made of chipboard that are manufactured off site and have hockey sticks and sockets fixed into them. The walls fit into a wooden track that has been fixed into the floor and ceiling. The walls are self-supporting, meaning that when the track has…


23 Tonne Prefabricated Roof

Robertson Homes brought in a 100 tonne crane to lift the prefabricated top back onto one of the historic towers of Great Glen Hall. The tower was one of the features damaged by fire in 2007, but has recently been lovingly rebuilt to its 19th-century glory. One of two being restored, the Western tower was the first to receive its…


Boltless Trapezoidal Tunnel Lining

The Carnwath Road Riverside tunnelling team have pioneered the design and use of a boltless trapezoidal tunnel lining. The design eliminates associated HAVS exposure for ring building operatives. Operatives no longer have to reach and stretch to get to bolt pockets with heavy spanners thus reducing manual handling risks. Noise levels are reduced which aids essential communication during ring building…


Temporary Fabrication Weather Proof Workshops

On site, several of our subcontractors have set up their own workshop areas in the compound. These workshops are set up for prefabrication of work before bringing materials and product into the construction zone. This benefits not only timing and labour costs, but also safety as workers do not have to work in trenches or excavations (fabricating pipework for example)….


Double Height Precast Columns

Ardmore have introduced the use of double-storey height, precast reinforced concrete columns which had the following benefits. Carbon footprint: With the concrete coming in precast, there is a vastly reduced number of vehicles on site, approximately 50%. Community: Now less vehicles are arriving on site, the impact on the community is greatly diminished. The public’s safety is increased with less…


Formfab Formwork Box

Traditionally pile cap formworks are constructed using plywood, individual steel pans, propping and dywidag bars, with handrails post installed by working at height with harnesses. On building S9 at the International Quarter London it was decided that a formfab box would be designed and manufactured off site to suit the pile cap size. This pre-fabricated steel form was purpose made…


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