Building Envelope Case Study: Hawarden Business Park, Flintshire

Two commercial units at the Hawarden Business Park in Flintshire are a veritable showcase of building envelope products from Panels and Profiles.

Buildings 2 and 3 both feature a mixture of Trisobuild System built-up construction, using four different profile types, and Trimapanel® System, the architectural wall panel system.

Situated six miles west of Chester city centre and within two miles of the A55, Hawarden Business Park is being developed through a partnership between Welsh Assembly Government and UK Land & Property and Pochins.

It is one of the Welsh Assembly Government’s most important strategic employment sites in North Wales. Located on the edge of Hawarden Airport and close to the Airbus UK factory at Broughton, the business park extends to 40.5 acres, with planning consent for considerable further expansion.

This masterplanned development can accommodate individual buildings up to 23,225m2 on fully serviced plots set within a landscaped environment and linked by all-new site infrastructure.

The Park’s buildings enjoy a BREEAM Very Good environmental assessment rating and are all equipped with a cutting-edge fibre-optic network. Another key element is the pristine appearance of the external envelopes of each unit, reflecting the high-tech nature of the surrounding area.

Lester Fabrications & Cladding were tasked with constructing the building envelopes for Plots 2 and 3, which needed to precisely match the aesthetics of existing surrounding units.

Lester Fabrications & Cladding responded to the challenge by selecting a wide range of Panels and Profiles products, deploying a combination of the Trisobuild System built-up system and the Trimapanel® System insulated panel system.

On the roofs, an insulated Trisobuild System built-up solution featured 3700m2 of R32 external weathering profile in Colorcoat Verso® 0.7mm in Goosewing Grey and 3700m2 of RL32 internal liner profile, in a white polyester finish, in tough 0.7mm gauge to safely accommodate roof traffic during the installation phase.

Colorcoat Verso® offers a superior alternative to leathergrain plastisol finishes. It uses a unique coating formulation and is supported by a guarantee for up to 30 years, providing improved performance at a competitive price. It is manufactured with a unique and subtle “C” emboss, providing instant visual reassurance that the product has been manufactured in the UK by Panels and Profiles.

The walls feature 2,300m2 of C32 profile in Colorcoat Prisma® 0.7mm in Oyster, plus 550m2 of 13.5/3 profile in Colorcoat Prisma® 0.7mm in Metallic Silver, for an attractive colour and profile contrast.

Further visual interest is added by the incorporation of 1000m2 of 70mm thick Trimapanel® System insulated architectural wall panel system in Colorcoat Prisma® in Alaska Grey.

The Trimapanel® System specification at Hawarden Business Park included mitred corner panels for exceptionally crisp corner detailing.

Trimapanel® System achieves the very highest levels of flatness, thermal and environmental performance, airtightness and structural capabilities.

Entirely manufactured in the UK utilising Colorcoat® materials for a minimised carbon footprint, Trimapanel® System provides the ultimate package of durability, fire performance, superior aesthetics, design
flexibility and outstanding environmental credentials.

Carrying full LPCB and FM fire performance approval, the system’s secret-fix joint design facilitates a quick, easy to install option for both horizontal and vertical cladding, with weather tightness far surpassing the requirements of BS EN 12865.

Trimapanel® System comprises a pre-finished steel liner profile, a Zero-ODP polyisocyanurate (PIR) insulation core and a micro-rib Colorcoat® pre-finished steel external weathering profile.

Colorcoat Prisma® was used exclusively on the walls of Buildings 2 and 3. Versatile, lightweight and strong, it is an ideal choice for contemporary, long lasting colour.

Offering outstanding UV resistance, Colorcoat Prisma® gives first-class colour and gloss retention, following comprehensive natural weathering testing in a variety of contrasting climates.

The complete colour range of Colorcoat Prisma® has been classed as Ruv4 in accordance with EN 10169:2010, the highest classification available, providing reassurance that buildings will retain their true colour for longer.

New Panels and Profiles CPD Seminar Launches

Panels and Profiles has just launched a new CPD seminar on best energy conservation design practice in industrial and commercial buildings.

“A guide to ADL2A: 2010 and the impact of Building Envelope systems” provides a detailed explanation of the new 2010 Edition of Approved Document L2A (Conservation of fuel and power in new buildings other than dwellings) to the Building Regulations 2010 (England & Wales).

Accredited by the Construction CPD Certification Service (CPDUK), the seminar demonstrates how to achieve compliance with ADL2A:2010. It examines the factors influencing the Simplified Building Energy Model (SBEM), using example buildings to show the effects of the new legislation.

The role of building control is also examined, along with an exploration of low carbon technologies. Time is also given to explain how to obtain energy performance certificates, plus a close look at the BRE Environmental Assessment Method (BREEAM).

The seminar is available to all professional practices throughout the United Kingdom. Anyone wishing to hold a seminar on their premises should email mark.clemson@tatasteel.com or call 01244 892106

Building Envelope Case Study: Carlson Filtration, Butts Mill, Barnoldswick, Lancashire

Carlson Filtration Ltd was established in 1923 and has been based at Butts Mill in Barnoldswick, Lancashire since 1950. The company has developed a strong market position in filtration equipment and filtration media in various forms, from depth filter sheets to high performance cartridges.

From the whisky, wine and brewing industries through to the clarification of fruit juices and filtration in the pharmaceutical, chemical and food industries, Carlson Filtration develops, manufactures, markets and distributes a broad range of products to suit all applications.

Originally built in the 1800’s, but extensively altered since then, the company’s home was a former textile mill and, as Managing Director Brian Gabbett explained, it was not without its share of problems.

“It was a typical old fashioned factory with a northlight roof and all the associated access and logistical disadvantages. The northlight roof was supported by cast iron columns. We had a very low roof height, limiting our storage capacity. The rooflights also suffered from UV degradation and had been replaced many times.

“The thermal efficiency left a lot to be desired too. At times it felt like we were heating half of Barnoldswick in the winter. The roof leaked and we had to issue umbrellas when people visited us in wet weather, which was embarrassing of course.

“Then about four years ago, we were approached by a developer with a view to purchasing the site and building a supermarket. This was a complicated exercise. Planners ultimately turned down the proposals, but we had carried out a range of feasibility studies that raised questions about our future direction.

“We are part of a small international group and looked at a number of strategic issues. The outcome of our deliberations was that it was clear that the output and activity of the UK operation was vital for our group’s future.

“We therefore recognised that we needed to find a permanent solution to the problems we had experienced with the existing building. In the past we had patched the roof up, with only limited success. So we asked consulting engineers to look at a long term answer.

“We could have undertaken further extensive repairs, but gradually began to consider an entirely new building.

“One of our key objectives was to remain in production, as we couldn’t afford to be out of commission for an extended period.

“We then examined a radical answer that would enable us to remain on the existing Barnoldswick site – building a new factory facility over the old one, enabling us to maintain production as work continued.

“We started building work in May 2010. Indeed production was only ever halted for a few hours as the foundations and steelwork was started.”

Once the steelwork was in place, a crash deck and safety netting was installed to maintain a safe working environment during roof construction. Following this, 100mm deep Trisomet® 333 System roof panels in Colorcoat® LG in Mushroom and 80mm deep Trisomet® 333 System wall panels in Colorcoat® LG in Merlin Grey were installed by Norwest Industrial Roofing Limited of Lowton, Warrington, Cheshire. The installation took place prior to Carlson Filtration’s traditional summer fortnight shutdown, which was extended by a further week to enable demolition of the old mill to be completed and services to be installed.

Colorcoat® LG pre-finished steel is an ideal solution where good performance is required at a competitive price. It has a leathergrain plastisol finish with an abrasion resistant top-coat and good corrosion resistance. It is available with a performance guarantee for up to 25 years.

Week three of the shutdown saw HVAC, electrical and safety equipment installation. Cladding rails were simultaneously assembled to make way for the 80mm deep Trisomet® 333 System wall panels.

Featuring a straightforward side lapping detail, the Trisomet® 333 System affords faster installation and a wider-spaced trapezoidal steel external skin, providing optimised water drainage, strength and walkability. Its autohesively bonded polyisocyanurate (PIR) insulation uses the latest foam technology, providing exceptional thermal performance from a relatively shallow foam core, enhanced environmental benefits, together with fire performance approved by the Loss Prevention Certification Board (LPCB).

The Trisomet® 333 System is ideally suited to fast track projects such as Carlson Filtration. It is manufactured under factory-controlled conditions, facilitating an “all-in-one” modular panel that enables the speed of construction to be increased, allowing the project to be completed within the required timescales, bringing overall savings in terms of cost and time.

Norwest Industrial Roofing Project Co-ordinator Wayne Briddon was full of praise for the speed and efficiency of the Trisomet® 333 System installation: “The fact that we were installing the system during a factory shutdown made a fast, problem-free build programme essential. Trisomet® 333 was therefore a perfect choice for this project, providing us with a far better solution than a more traditional built-up system, especially in terms of its rapid and extremely straightforward fixing properties.

“It was competitively priced and we liked working with it, encountering no problems at all. The completed building looks really good.”

Reflecting on the project, Brian Gabbett commented: “One key benefit we now have is the superior building height that has been afforded by having to construct the new structural steel frame over the old building. We now have a building height that ranges from 6.2 metres at the lowest eaves to 8 metres at the ridge. This has significantly increased our warehousing capacity.”

Panels and Profiles launches enhanced Trimapanel® System

Trimapanel® System, the insulated micro-rib architectural wall panel system has just been extensively re-engineered to achieve the very highest levels of flatness, thermal and environmental performance, airtightness and structural capabilities.

Entirely manufactured in the UK utlilising Colorcoat® materials sourced from Colors, Shotton for a minimised carbon footprint, Trimapanel® System now provides the ultimate package of durability, fire performance, superior aesthetics, design flexibility and outstanding environmental credentials.

Carrying full LPCB and FM fire performance approval, the system’s secret-fix joint design facilitates a quick, easy to install option for both horizontal and vertical cladding, with weather tightness far surpassing the requirements of BS EN 12865.

Trimapanel® System comprises of a pre-finished steel liner profile, a Zero-ODP polyisocyanurate (PIR) insulation core and a micro-rib Colorcoat® pre-finished steel external weathering profile. It can be specified in a wide range of colours, in Colorcoat HPS 200 Ultra® and Colorcoat Prisma® pre-finished steel as standard.

The system is available with the unique Platinum System Warranty, combined with Confidex® and Confidex Sustain® guarantees for a CarbonNeutral solution, providing unrivalled peace of mind for up to 40 years.

Trimapanel® System is manufactured using responsible sourcing and traceability of all component materials. All steel elements are produced within the UK through our production, strip processing, galvanising, coating and profiling facilities. The system’s carbon footprint is further minimised by the manufacturing process being situated adjacent to the Colorcoat® and galvanising lines.

Available in three cover widths, Trimapanel® System is an ideal partner for the Trisomet® 333 System insulated panel, providing a comprehensive single-source roof and wall cladding solution, all covered by the unique Platinum warranty.

The system also includes a wide range of flashings, ancillaries, an integrated window system, and fabricated corner and curved panel options. Primary fasteners for securing the Trimapanel® System to structural steel have been purpose-designed to provide high speed fixing and structural security with reduced risk of over compression, along with minimal thermal bridging.

All Trimapanel® System steel elements are 100% recyclable. The insulation and steel can be separated using existing shredder plants after which the materials can be recovered or recycled.

In common with all our building envelope solutions, Trimapanel® System offers a full technical support service, including extensive design assistance, both online and in the field.

Detailed information is now available at the Trimapanel® System micro-site at
www.trimapanel-system.com

New Building Envelope Case Study : Eddie Stobart

I’ve just uploaded a new case study to our website: Eddie Stobart in Widnes.  This project uses 12,000m2 of Trisomet® 333 Insulated panels in white. Its certainly an impressive case study and we’ve got some great photos which you can view by clicking on the gallery tab. You can also download the full case study as a PDF on the page.

To view the case study, click here

Corus Panels and Profiles releases updated wall chart for 2010

Corus Panels and Profiles has released an updated wall chart for 2010. This new wall chart incorporates both Building Envelope and Structural Products and allows for easy comparison between the full range of products.

The Building Envelope product range encompases the insulated panel systems Trisomet® 333  System and Trimapanel® System along with a comprehensive range of engineered built-up roof and wall cladding systems.

The Structural Products range comprises ComFlor® composite floor decks, from 46mm to 225mm deep and structural roof decking from 32mm to 210mm deep.

To download the new wall chart, click here

To request an A1 print copy, click here