The mill, which was previously used by Joseph Heap and Sons, once ground rice for Kellogg’s Rice Krispies. It is one of the last surviving warehouse complexes in the area.
Demonstrating the speed and efficiency of offsite construction, the Metek team delivered the frame to a 31-week programme.
At a Glance
Logistically, space on the project was restricted with existing buildings in close proximity on three elevations and a public access road on the remaining elevation. Therefore, standard scaffold was NOT the preferred option for the client and Metek had to provide their own edge protection system for the duration of their works. This was risk assessed and planned by our experienced Senior Contracts Manager to ensure this element didn’t delay the build process but also supported other trades. Therefore, just in time delivery of materials was critical to ensure the success of the project.
Construction Details
Metek work on the basis that ground or podium slabs (by others) are constructed to +/-5mm, allowing for up to 10mm in total of packing. The tolerance could be set as -0,+10mm or indeed-10,+0mm if agreed and advised upfront. Because of this, it’s very rare for sole plates or ring beams being formed due our tolerances being more generous than the industry norm.
To achieve the speed of build needed by this high profile development, Metek had to give due consideration to the height v’s footprint that made the bracing of the structure a key issue. The client didn’t want to entertain an RC core for the stairs / lift shafts, so Metek included as many load bearing walls as necessary to achieve this.
The footprint was only just over 500m2 so for the whole building, a GIFA of just over 5,000m2. Tall and thin just about describes it. At just 11no. apartments per level with 5no. on the GF, the 104no. apartments provided a mix of 1+2 bedroom spaces. To save cost, the twin walls between apartments were formed with non-load bearing stud partitions which saved on weight and cost.
The selection of LGSF as the construction methodology for the building enabled the build programme to be significantly reduced v’s more traditional means, enabling the wider site redevelopment to commence earlier. The gross weight of a light steel/composite floor solution is about a half v’s concrete frame with blockwork walls, excluding foundations, and for embodied carbon, 37% lower on a per unit floor area.
Application Benefits
- Rapid speed of construction for this residential project of 4,530m2 floor area
- Integrated construction system provided by Metek
- Carbon saving of around 30-37% against the original proposed method of construction
- Just in time delivery of materials to space restricted site
- Fire resistant and non-combustible
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The design and construction of the frame commenced at Level 1 from a podium slab structure to roof level. Coordination of design with apartment– communal areas / service requirements / door size / stair-core / lift-shafts / facade was critical and Metek’s design team worked in conjunction with the Architect / M+E / Fire / Acoustic consultants to ensure the correct solutions.
Logistically, space on the project was restricted with existing buildings in close proximity on three elevations and a public access road on the remaining elevation. Just in time delivery of materials was critical to ensure the success of the project.
Metek’s site team were well organised, reliable and efficient in ensuring delivery of materials and the successful erection of the structure.
