innovation and achievement 2009
TRANSCRIPT
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innovation and achievement 2009
showcasing achievements in construction products
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the voice of the industryThe Construction Products Association represents 85% by value of
all manufacturers and suppliers of construction products in
the UK, including the largest companies in the industry, as well
as 43 sector trade associations. Collectively, the industry provides
20% of goods manufactured in this country.
The Association acts as a single voice to promote and campaign
for the construction product manufacturers and suppliers in order
to support a growing and profitable industry. Its growing credibility
can be seen by the increasing influence it has with government
departments and other industry and political bodies.
the factsThe construction products industry is at the heart of the UK
economy, providing essential materials for our homes, schools,
hospitals, factories, offices, roads and railways.
Every year the industry:
• has an output of more than £40 billion
• exports in excess of 10% of output
Accounts for :
• 40% of total construction output
• 20% of the UK’s manufacturing output
• 4% of the UK’s Gross Domestic Product
• employs more than 500,000 people
• in almost 30,000 companies
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contentsMessage from the Chairman 5
Message from the Secretary of State, Department for Innovation, Universities and Skills 6
health, safety and security 7
Leaderflush Shapland Sentinel 9
Knauf Drywall Knauf Safeboard 10
Marley Waterproofing The Marley Waterproofing Hybrid Specification (HS) Roofing System 11
Tarmac National Contracting HAVmeter - an industry first to tackle Hand Arm Vibration Syndrome 12
CEMEX UK Cycling safety initiative to prevent accidents 13
Saint-Gobain PAM UK Ltd Hydraulic Pipe Unloading Beam 14
Aggregate Industries UK New bagged aggregates factory at Barton under Needwood 15
Ancon Building Products Ancon KS Threaded Anchor and Ancon Keyblock Re-useable Pocket Former 16
Filon Products Limited Fixsafe 17
HCP, an SAS International Group Company Dutch-fold anti-ligature radiant heating panels 18
SWS UK SeceuroVision 7501 19
energy and carbon saving 20
Marantec UK a division of Link Controls Ltd Marantec blueline technology (currently available in Comfort 220.2 blueline) 22
The BSS Group plc Contactor Supply Facility 23
Halfen Ltd and Cityroofs Ltd Aquadyne Living Wall 24
Kingspan Insulation Limited Refurbishment of The Victorian House of the Future, Camden 25
Baxi Group Baxi Ecogen 26
Permanite Engineered Roofing Systems PermaTEC EcoWRAP 27
Aggregate Industries UK Low Temperature Asphalt 28
Aggregate Industries UK Urban Surface Protection used on Charcon StoneMaster 29
Baxi Group Multifit GasSaver 30
Celotex Celotex FR4000 and CG4000 31
Freerain Limited G-Tanks 32
Hanson UK Frindsbury Wharf marine sand and gravel processing plant 33
Kingspan Insulated Panels Kingspan WoodTherm™ 34
Knauf Insulation Mineral Wool with ECOSE® Technology 35
Polypipe Ventilation The Domus Fresh Air Supply Set 36
Senior Architectural Systems Ltd Hybrid Timber/Aluminium Fenestration System 37
SIG Insulations Insulslab SFRC (Steel Fibre Reinforced Concrete) 38
SupaWall Limited SupaWall®, SupaRoof® and SupaFloor™ Panels 39
Kingspan Insulated Panels Kingspan Render Panel 40
Kingspan Insulated Panels Kingspan Thermatallic™ 41
EDGETECH IG INC Super Spacer® TriSeal™ Premium 42
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contents improvements in site efficiency 43
IBP Conex Ltd. Conex Push-Fit 45
Hilti (Gt Britain) Limited Hilti X-HS-W wire hanger system 46
Laidlaw Solutions Limited Laidlaw Orbis Integra Doorsets Range 47
Lafarge Readymix Integrated onboard slump process control system 48
Hanson Building Products Hanson Quick Build™ Prefabricated clay brickwork masonry as part of flood defence system 49
Reynaers Ltd Optima 50
Aggregate Industries UK Lewisham Flag Paving Development 51
DrillVent UK Limited DrillVent 52
EcoTherm Insulation UK ltd UFH board 53
Hanson Building Products SPS Factory Management System 54
Kingspan Insulation Limited Kingspan ‘Roof in a Box’ 55
Saint-Gobain Isover ULTIMATE™ Protect 56
SAS International SAS Modular Solutions 57
SmartPly Europe Ltd SmartPly SiteProtect 58
FP McCann Ltd Easi-Base 59
resource efficiency 60
ICI Paints AkzoNobel Dulux Trade Paint Solidifier 62
Aggregate Industries UK Dry Grinding and Polishing 63
Filon Products Limited GRP (Glass Reinforced Polyester) Recycling 64
Johnson Tiles - (a trading division of Norcros Group (Holdings) Limited) Ink-jet Decoration of Ceramic Tiles 65
ACO Technologies plc VIENITE® 66
Profile 22 Systems Northwards Pilot – 100% Recycled Windows installation 67
CEMEX UK Readyflow®; a new concrete block permeable paver 68
Hanson UK Recycled road planings dryer 69
Hanson UK Recycling inorganic waste for use in cement 70
Lafarge Readymix Use of by-products within concrete 71
Milliken Contract Omni® Access All Areas with Tractionback™ 72
Profile 22 Systems 60% recycled content window system 73
Swish Building Products Sustainable Rainwater System 74
Further examples for each category are available on our website www.constructionproducts.org.uk
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innovation and achievement 20095 construction products association
As Chairman of the Construction Products Association I am delighted once again, to have this opportunity to introduce the latest edition of Construction Products Innovation and Achievement. The CPIA, now in its sixth year, is firmly established as the leading showcase for some of the most innovative products and processes that have been developed by the industry during the last year or so.
It does not need me to remind you that the UK economy has
been experiencing its sharpest decline since 1948 and that the
construction industry has suffered more than most during this
decline. Yet, despite these unprecedented times, the industry
continues to look to the future, embracing innovation and
improvement as it strives to deliver new and exciting solutions to
all parts of construction. Companies understand only too well the
competitive edge that innovation brings them and the importance
that they place in ensuring creativeness is a key part of current and
future commercial success.
The construction products industry has proved once again, its
enormous ability to lead, by devising new, more efficient, more
sustainable ways of doing things. As you will see from the range of
products and processes in this publication, the creative and innovative
approach is not confined just to a select few, in one or two sectors,
but can be seen as a key driver for an industry that is continuously
improving and constantly changing.
By delivering efficiencies and creating more sustainable solutions,
these new ideas bring a range of benefits to everyone including
clients and end users, company employees and especially the
environment in which we live.
The interest shown by companies from across the industry to this
year’s CPIA is hugely satisfying and demonstrates the enormous
desire that companies have to participate and promote their exciting
innovations to the wider world.
It is always a difficult decision deciding which product or process
to feature, but you can be sure that for each one chosen there
are plenty of others that could equally demonstrate the innovative
achievements and exciting development of the construction
products industry - a selection of other examples is available on the
Association’s website.
CPIA was always intended to show how the industry as a whole is at
the forefront of innovation, improvement and change. At this time of
economic uncertainty, we can be proud that our industry continues
not only to aim high but also to deliver this range of solutions and
improvements.
Adrian Barden
Chairman Construction Products Association
message from theconstruction products association chairman
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innovation and achievement 2009 6construction products association
I am delighted to provide the opening words to this publication. Not only is it an opportunity to introduce myself and the new department, it’s also a chance to commend construction product manufacturers and suppliers for their hard work and commitment in these difficult economic times.
I want to start by saying how encouraged and impressed I am by the
resilience and determination construction firms have shown over
the past 12 months. This publication is evidence that Britain is still a
nation of innovators, delivering products and solutions that will shape
the industry in the years ahead.
As many of you will know, the Department for Business has now
merged with part of the former Department for Innovation,
Universities and Skills, pulling together the key elements we believe
are necessary to help us shape the economic future of this country.
As part of that merger I have been appointed as Business Minister
at the newly formed Department for Business, Innovation and Skills
(BIS) with responsibility for the construction sector.
My priority is to help our construction companies in the current
economic climate. That’s why in the 20008 Pre-Budget Report we
brought forward £3 billion of capital spending from 2010-11 into
2008-09 and 2009-10. We must make sure this money is spent on
time and well.
In my first few weeks in post, I have met and heard from a number of
representatives of the sector. It is clear we must ensure investment
is going where it’s needed so that new products and services
continue to emerge. Indeed, as competition for every job and every
new contract intensifies, it is essential that we continue producing
innovative, groundbreaking products like Permanite’s Perma TEC
EcoWRAP and Knauf Insulation’s Mineral Wool with ECOSE
technology. These are examples of British firms moving into the low
carbon economy, using sustainable products and services to generate
new capital.
I am convinced that this should be the focus of every company
throughout the construction chain – to build a fully sustainable
construction sector. Sustainability means not only meeting our
environmental objectives and improving resource efficiency but
contributing to long term economic growth and job creation. The
Strategy for Sustainable Construction launched last year lays down
steps we must take to achieve that.
The Budget 2009 announced £1.4 billion of spending to support the
low carbon sector. A significant proportion of this spending will feed
into the construction sector by encouraging the deployment of low
carbon technologies and supporting energy and resource efficiency
for households and businesses.
Our strengthened position as BIS means we can now work more
closely to ensure we provide the support businesses need. We
have set aside more than £600 million from our training budget to
tackle skills issues in key sectors, with £133 million earmarked for the
construction sector. We’ll also use government contracts to ensure
those firms that benefit can train more staff.
The message I want to get across is that there is life after recession
and our success relies on our ability to plan for tomorrow. We must
build on our strengths ensuring our firms are ready for the upturn
and with innovative companies, like those displayed in this publication,
I firmly believe we can and will do that.
Ian Lucas
Minister for Business, Department for Business, Innovation and Skills (BIS)
message from the minister for business, department for business, innovation and skills (BIS)
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innovation and achievement 2009health, safety and security
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As set out in the Approved Code of Practice for the Construction Design and Management Regulations, there is significant emphasis on the duty of designers to consider safety throughout the whole life cycle of the building, from construction, through to usage and including end of life decisions. Designers and Specifiers can help meet their obligations under CDM
by choosing products that improve safety both for installers and users as well as enhance security, which is also of increasing concern.
Manufacturers have again responded positively with a variety of products and solutions addressing some of these key responsibilities.
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innovation and achievement 20099 construction products association
innovation and achievement 2009health, safety and security
Leaderflush Shapland SentinelSentinel (patent pending) is an innovative hand and finger
protection solution that allows specifiers and architects to
achieve outstanding performance, without compromising design
or architectural integrity. Sentinel uses a pivoted design with
decorative timber elements as an integral part of the doorset.
The ergonomic, smooth design has no dirt traps enabling easy
cleaning and the lacquer contains Hygienilac® antimicrobial
protection. Sentinel provides effective and unobtrusive finger
protection whilst guaranteeing the highest levels of performance
– Approved document M and BS8300 compliant opening forces,
30 minutes fire resistance and 30RwdB acoustic performance.
Seals and essential ironmongery are included, eliminating the risk
of certification problems and also negates the need for on-site
trades fitting retro-fit components. Sentinel is environmentally
friendly as well as being one of the most effective and unobtrusive
finger protection solutions in the marketplace with all materials
used in the manufacture either FSC accredited or FSC neutral.
What is innovative or new?
Sentinel is one of the most unobtrusive finger protection
solutions in the marketplace. Being an integral part of the
doorset, it cannot be forcibly removed negating the cost of
ongoing replacement and the need for on-site trades fitting
unsightly, retro-fit components.
How are benefits delivered?
30,000 children trap and seriously injure their fingers in doors
every year and more than 1500 of these children will need
surgery, according to the Royal Society for the Prevention of
Accidents (ROSPA). Sentinel is specifically designed to help
guard against hand and finger injury whilst ensuring the highest
levels of performance in a discreet and aesthetically pleasing
hand and finger protection solution.
Contact details
Address: Leaderflush Shapland
Milnhay Road
Langley Mill
Nottingham
NG16 4AZ
Telephone: 01773 530500
Facsimile: 01773 530040
Email: [email protected]
Website: www.leaderflushshapland.co.uk
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innovation and achievement 2009 10construction products association
innovation and achievement 2009health, safety and security
Knauf Drywall Knauf SafeboardKnauf Safeboard is a standard plasterboard containing barium.
For projects that require x-ray shielding, it completely removes the
need for lead-lined plasterboards in almost all cases. For more than
100 years, hospitals, dentists’ practices, veterinary surgeries and
industrial laboratories have required varying degrees of lead-lined
partitions to shield the adjoining areas from radiation. Until this
year, the use of lead has been commonplace within public buildings.
This is no longer necessary as Knauf Drywall has been working with
the Health and Safety Executive to agree on equivalent ratings for
partitions that will not only remove a high percentage of lead used,
but also the need for specialist contractors onsite. This allows
traditional dry lining firms to pitch for entire hospital projects.
Launched with Wardray Premise, the UK’s leading x-ray shielding
specialist, specifiers and contractors can be confident that it is
supported by the most respected bodies in the industry.
What is innovative or new?
Lead has been integral to x-ray blocking ever since the harmful
effects of radiation had been discovered. For the first time,
walls can shield adjoining areas without the use of lead. This not
only solves the inert concerns of installed lead, but the inherent
concerns of installation, customisation and disposal.
How are benefits delivered?
Not only the obvious benefits of removing lead from new
buildings and replacements for refurbishments; but also the
weight is greatly reduced (aiding manual handling concerns),
contractors constructing the rest of the project will be able to
install the partitions without the need to source and hire
specialist labour (significant cost and time benefits) and it
becomes extremely simple to modify the use of rooms at a later
date (adding radiation shielding or upgrading refurbishments).
Contact details
Contact: Stuart Hiscott
Address: Knauf Drywall
PO Box 133
Sittingbourne
Kent
ME10 3HW
Telephone: 01795416282
Facsimile: 0800 521 205
Email: [email protected]
Website: www.knaufdrywall.co.uk
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innovation and achievement 200911 construction products association
innovation and achievement 2009health, safety and security
Marley Waterproofing The Marley Waterproofing Hybrid Specification (HS) Roofing SystemMarley Waterproofing’s HS System provides a practical, modern
design solution for traditional built-up roofing. Benefits of high
performance materials and specific project criteria, are combined
to provide a specification that designs out risks and ensures that
requirements of CDM, Building Regulations and British Standard
Codes of Practice are not compromised. A key element is design
detailing using the latest cold-applied technologies (minimum of
0.5m around all roof details).
The HS System comprises:
• Cold-applied build-up - high performance vapour control layer;
premium insulation; self-adhesive underlayer
• Traditional torch-on or pour and roll capsheet
• Cold-applied detailing
This warm roof build-up meets Part L requirements:
• Insulation/detailing protected during application of top waterproofing layer
• Enables specification of a more thermally efficient insulation
Cold application is ideal for projects where bitumen boilers/gas
torches are impractical, resulting in a reduction in the level of
fumes/CO2 emissions.
What is innovative or new?
The HS System is a new generation of roof design, specifying a
mix of the latest technologies to minimise risk during installation,
whilst maintaining a traditional finish.
Marley Waterproofing has addressed market changes, using its
experience to provide a best fit solution with an all
encompassing single point guarantee.
How are benefits delivered?
• Complies with regulations such as Part L
• Environmental benefits from reduction in fumes and CO2 emissions
• Cold detailing and pre-formed details minimise time spent at perimeter thereby reducing risk from falls at height
• Choice of cold applied technologies – such as self-adhesive/liquid applied
• Fire retardant capsheet
• Single point guarantee covering all materials, design and workmanship, up to 20 years
• Approved and trained contractor/installer network
Contact details
Contact: Beth Barber
Address: Marley Waterproofing
Covert Road
Industrial Estate
Aylesham
Kent
CT3 3EQ
Telephone: 0844 815 6463
Facsimile: 0844 815 6462
Email: [email protected]
Website: www.marleywaterproofing.com
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innovation and achievement 2009 12construction products association
innovation and achievement 2009health, safety and security
Tarmac National Contracting HAVmeter - an industry first to tackle Hand Arm Vibration SyndromeDeveloped by Tarmac National Contracting and Reactec,
a specialist noise and vibration company, the HAVmeter, is the first
system to provide ‘live’ data on tool operators’ cumulative daily
exposure rates to Hand Arm Vibration (HAV).
Current HSE guidance sets the daily Exposure Action Value (EAV)
at a level of 2.5 m/s2 A(8). However, Tarmac identified that the
critical issue for its staff and the wider construction industry is how
daily dosage is monitored and recorded across each piece of
equipment used.
The HAVmeter system features four main components: a colour-
coded tool tag on each piece of equipment; a magnetic swipe card
for each operator; and a base station within the crew bus, which
incorporates up to eight individual HAVmeters.
Information including tool manufacturer, model, unique ID and
average tool vibration level is automatically uploaded into the
HAVmeter. When the operator is approaching their maximum
HAV exposure level, the HAVmeter provides a visual warning.
What is innovative or new?
Individual tools carry different vibration levels and operators use
a number of tools each day making it difficult for operators and
employers to assess the actual levels of HAV exposure.
This is the first device to calculate cumulative live vibration data
across all vibratory tools used by an employee throughout the day.
How are benefits delivered?
The HAVmeter system has significantly reduced around 1,100
Tarmac employees’ exposure rates to HAVs from vibrating tools.
The system has further increased the accuracy of Tarmac’s health
and safety data, eliminating the need for operators to complete
daily paper-based records of vibration levels and allowing Tarmac
to monitor individual dosage levels more effectively.
Contact details
Contact: Glyn Williams
Address: Tarmac National Contracting
The Village
South Normanton
Derbyshire
DE55 2DS
Telephone: 01902382578
Facsimile: 01902382556
Email: [email protected]
Website: www.tarmac.co.uk/nationalcontracting
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innovation and achievement 200913 construction products association
innovation and achievement 2009health, safety and security
CEMEX UK Cycling safety initiative to prevent road traffic incidentsAccording to the Department for Transport collisions between
large vehicles and cyclists account for approximately 8% of those
killed or seriously injured on the roads. This is an issue for the
construction industry which transports the majority of its materials
by road.
Investigations undertaken by CEMEX shows that there is a
particular risk of incidents at road junctions and when cyclists are
on the nearside of vehicles turning left.
To improve road safety, CEMEX has introduced the following features:
• A new mirror (fish eye) to improve visibility to the near side (blind spot) and front of the vehicle
• A cyclist warning sign to the nearside rear of all of our vehicles, warning of the dangers of undertaking Large Goods Vehicles (LGV)
• The company is also now investing in the fitment of the proximity sensor ‘side-scan’ system on all new fleet to warn the driver if anything is in the danger zone to the left side of the vehicle
• CEMEX is also undertaking the fitment of side under-run bars on tippers, as extra protection for cyclists and other vulnerable road users. These have been a good anchor point for additional warning signs
What is innovative or new?
Since 2005 CEMEX has had a continuing programme of
introduction and innovation of safety features, the latest of
which is the proximity sensors system. CEMEX UK has a
company fleet in excess of 450 large goods vehicles, including
concrete mixers, aggregate tipper lorries, cement tankers and
‘curtainsiders’. In addition, there is a fleet of independent
haulage contractors comprising of up to 4500 vehicles,
dependant on market volume.
How are benefits delivered?
Since 2005 there have been no blameworthy cyclist fatalities or
serious injuries related directly to vehicles turning at junctions.
From 2000 – 2005, there were two fatalities and four serious injuries.
• Drivers are less affected by road traffic incidents as there are fewer
• Visible demonstration to public that the construction industry take safety seriously
• Reduced negative PR
Contact details
Contact: Andy Taylor, Director of Health and Safety
Address: Wolverhampton Road
Oldbury
West Midlands
B69 4RJ
Telephone: 0121 569 7455
Email: [email protected]
Website: www.cemex.co.uk
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innovation and achievement 2009 14construction products association
innovation and achievement 2009health, safety and security
Saint-Gobain PAM UK Ltd Hydraulic Pipe Unloading Beam With more than one fifth of all reportable UK work-related
accidents occurring near vehicles, site unloading of pipes and
associated fittings is a potentially high risk operation. Where forklift
access is not possible, unloading is usually completed by use of
cranes or HIAB vehicles, both of which involve accessing the trailer
bed, either to apply slings, or attach pipe hooks.
Remotely controlled from ground level, the Hydraulic Unloading
Beam is manoeuvred into position on top of a ductile iron pipe and
the pipe hooks contracted to fit snugly over the pipe ends.
Each pipe is unloaded and positioned on the ground with the same
effectiveness as a standard HIAB. Access to the trailer bed is
eliminated and there is no damage to the pipes.
Use of the unloading beam is now specified by many customers and
has led to further developments using other attachments to allow
unloading of pipe bundles and pallets in the same manner.
What is innovative or new?
Traditional methods of site off-loading of heavy pipes and fittings
requires some personnel access to the trailer bed. The Hydraulic
Unloading Beam with purpose designed attachments can be
remotely controlled outside the working area during unloading.
Attachments for the safe unloading of individual pipes, pipe
bundles and pallets can be remotely and quickly changed over.
How are benefits delivered?
Within the Working at Height Regulations (2005), dutyholders
are charged to ‘avoid work at height’ if possible.
The Hydraulic Pipe Unloading Beam:
• Removes the need for operatives to access the trailer bed when unloading heavy pipes and fittings
• Removes the problems of sling attachment and ‘balancing’
• Provides a clearly defined ‘exclusion zone’ during offloading and stacking
• Provides a proforma method statement and risk analysis that can be provided to a contractor before deliveries commence
Contact details
Contact: Dr David Smoker
Address: Lows Lane
Stanton-by-Dale
Ilkeston
Derbyshire
DE7 4QU
Telephone: 0115 930 5000
Facsimile: 0115 930 0702
Email: [email protected]
Website: www.saint-gobain-pam.co.uk
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innovation and achievement 200915 construction products association
innovation and achievement 2009health, safety and security
Aggregate Industries UK New bagged aggregates factory at Barton under Needwood The old bagging process at a previous site involved workers being in
the same area as fork lift trucks and also hand stacking bags of
aggregate. The new process had the principle of keeping men
inside the factory, and mobile plant outside. The process was
redesigned from scratch, with the bulk aggregates being deposited
outside the factory, and a conveyor belt system then removing them.
The only manual operation is the loading of a bag onto the weighing
arms, which is then filled automatically once the operative is safely
behind a light curtain. The bagged material is then removed from
the factory by conveyor, again eliminating contact between man and
machine. Also on the site, a special area has been set aside for
vehicle sheeting, totally out of the way of all plant. Walkways have
also been totally reorganised with barriers between men and
transport at all times.
What is innovative or new?
A conscious decision has been taken to make sure there is no
interface between mobile plant and machinery. Also light activated
safety curtains are used to prevent the operation of bagging
machinery where men are present. This plant can be described
as ‘state of the art’ and is highly efficient.
How are benefits delivered?
The process change is designed to deliver maximum health and
safety benefits. It eliminates manual handling and also keeps
men and mobile plant totally separated. The idea was to create
a site that could be viewed as a template for safe working and
serve as a model throughout the company.
Contact details
Contact: Paul Lane
Address: Aggregate Industries
Hulland Ward
Nr Ashbourne
Derbyshire
DE6 3ET
Telephone: 01335 372222
Facsimile: 01335 370973
Email: [email protected]
Website: www.aggregate.com
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innovation and achievement 2009 16construction products association
innovation and achievement 2009health, safety and security
Ancon Building Products Ancon KS Threaded Anchor and Ancon Keyblock Re-useable Pocket FormerThe Ancon KS Threaded Anchor is manufactured from high strength
steel and features a machined internal metric thread.
It is cast into a concrete face and can be used with either an Ancon
parallel threaded reinforcing bar as a continuity system at a wall-to-slab
joint or a standard metric bolt fixing.
A line of KS Anchors are installed quickly and accurately at the required
spacing, using the Ancon Keyblock which is a re-useable HDPE mould.
The KS Anchors are inserted into the Keyblock and this unit is then
nailed to the formwork. Reinforcement is installed around the unit
and the concrete is cast. The formwork is then removed to reveal
the Keyblock, which is left in place to protect the internal threads
until they are required.
When the Keyblock is eventually removed it is retained for use
elsewhere on the same site or on a future project.
What is innovative or new?
This system is innovative in three ways:
• It uses a threaded anchor as a wall-to-slab continuity system
• It combines the use of a threaded anchor with a re-useable pocket former
• It uses a re-useable mould to evenly space a line of threaded anchors
How are benefits delivered?
• This system can be used to replace a continuity box containing pre-bent bars. It improves site safety by eliminating the manual process of straightening these bars on site
• The KS Anchor replaces hooked bars in the wall thereby reducing congestion in the concrete. It also eliminates the need to drill concrete to create a fixing point, eliminating the use of power tools and exposure to hand-arm vibration
• Use of the Keyblock increases the load capacity of the KS Threaded Anchor by providing additional embedment in the concrete. Being re-useable it reduces dependency on virgin materials
Contact details
Contact: Annabelle Wilson
Address: Ancon Building Products
Telephone: 0114 275 5224
Facsimile: 0114 276 8543
Email: [email protected]
Website: www.ancon.co.uk
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innovation and achievement 200917 construction products association
innovation and achievement 2009health, safety and security
Filon Products Limited FixsafeThe Fixsafe System has been designed to allow profiled roof sheets
or rooflights to be replaced from below, eliminating the need to
access dangerous fragile roofs, thereby increasing safety for
maintenance operative and equipment erectors, greatly reducing
the risk of serious injury or death. By removing the requirement
for costly safety netting, roof staging, fall protection or external
scaffolding, access equipment costs are minimised and on site time
is reduced. The speed and ease with which roof repairs can be
carried out using the Fixsafe System brings important advantages to
building owners, with reduced disruption and safer working
procedures. The Fixsafe System allows those involved in repairing
fragile roofs to work fully in compliance with Regulation 9 of
the Working At Height Regulations, 2005. The Fixsafe System
comprises of specific GRP translucent or opaque replacement
sheets to match all popular asbestos and fibre cement profiles and
includes the patented fixings.
What is innovative or new?
Eliminates the need to access fragile roofs from above and all
the dangers that this involves. By allowing broken roof sheets to
be replaced from below from the safety of a cages access point
via a cherry picker or scissor lift.
How are benefits delivered?
Allows contractors to fully comply to Regulation 9 of the
Working At Height Regulations, 2005. The cost savings have
been proven as against traditional methods for access.
The biggest benefit is that lives will be saved (in the development
process since 2001, 147 people have died falling through fragile
roofing material).
Contact details
Contact: David Hathaway
Address: Unit 3, Ring Road, Zone 2
Burntwood Business Park
Burntwood
Staffordshire
WS7 3JQ
Telephone: 01543 687 300
Facsimile: 01543 687 303
Email: [email protected]
Website: www.filon.co.uk
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innovation and achievement 2009 18construction products association
innovation and achievement 2009health, safety and security
HCP, an SAS International Group Company Dutch-fold anti-ligature radiant heating panelsThe principle behind radiant heating panels involves the bonding of
a serpentine copper heating element to the rear of an aluminium
panel. Mounted in the ceiling or freely suspended from the soffit,
hot water flows through the element creating a warm surface.
Like the suns rays this warm surface emit electromagnetic radiation,
heating room occupants, contents and surfaces directly. Because
large volumes of air do not need to be heated before occupants feel
the benefit, the use of radiant heating panels can lead to a reduction in
the amount of energy needed to heat a space.
SAS international, through its specialist heating division HCP,
has developed a new anti-ligature radiant heating panel for use in
secure facilities such as mental health units and prisons.
What is innovative or new?
The new ‘Dutch-fold’ design allows radiant heating panels to be
directly mounted to the ceiling without the need for a separate
mounting frame; this is a unique method of manufacture.
The material used to construct radiant heating panels is ‘folded’
back upon itself. The design helps to reduce installation time
and ensure panels sit tight to the ceiling and a ligature can not
be affixed.
How are benefits delivered?
Ceiling-mounted Dutch-fold anti-ligatures panels create a safer
and more secure environment for both patients and inmates by
reducing the chances of accidental burning and reducing
opportunities for self-harm.
Radiant heating solutions are increasingly specified in the healthcare
and educational sectors, where the benefits of freeing up floor
and wall space, and integration with natural ventilation strategies
are well recognised. Additionally they can contribute towards
reduced cleaning regimes and help meet infection control
targets by reducing the cross infection risks associated with
other systems.
Contact details
Contact: John Staunton
Room Comfort Brand Manager
Address: 31 Suttons Business Park
London Road
Reading
RG6 1AZ
Telephone: 0118 929 0900
Facsimile: 0118 929 0901
Email: [email protected]
Website: www.sasint.co.uk
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innovation and achievement 200919 construction products association
innovation and achievement 2009health, safety and security
SWS UK SeceuroVision 7501The SeceuroVision 7501 steel roller shutter is the first and only
vision shutter to be tested by the LPCB to LPS 1175-1 and to be
approved to Police and insurance standards. The SeceuroVision
7501 has been designed by SWS UK’s dedicated product
development team building on the existing features of the market
leading steel commercial shutter range.
This product can be manufactured using either a traditional
commercial shutter design incorporating steel angles and guide
channels or using a more aesthetically pleasing continental design
which has extruded aluminium guide channels and box.
The testing to the LPCB’s rigorous LPS 1175 Issue 6 burglary
resistance standard, where it achieved a Level 1 rating, proved
the shutter resistant to attacks from intruders using a variety of
tools, including levers, screwdrivers and knives. These are the type
of concealable tools that are used by the opportunist thief.
What is innovative or new?
The SeceuroVision 7501 is the only vision shutter on the market
to achieve the highly regarded Loss Prevention Certification
Board’s (LPCB) LPS 1175 Issue 6 burglary resistance standard and
has also obtained ACPO’s prestigious ‘Secured by Design’ status.
Delivering up to 25% vision, this product provides a solution to
meet the demands of both security and product display.
How are benefits delivered?
Business crime has risen 20% since 2004. The most targeted
areas are industrial estates and shopping parades where more
than 70% of businesses have experienced crime in the last 12
months. With the current economic climate there has never
been a more important time for businesses to protect their
property. However, government community safety guidelines
restrict the use of shutters as a security method and often the use
of solid shutters is not allowed. The SeceuroVision 7501 offers
a comprehensive solution to a number of criteria. It provides
effective protection for businesses by offering the highest level of
security whilst also complying with government regulations.
The result is secure yet open and welcoming urban environments
which maximise the potential for window shopping.
Contact details
Contact: Melloney Jewell
Address: SWS UK
Hornby Road
Claughton
Lancaster
LA2 9LA
Telephone: 01524772413
Facsimile: 01524772411
Email: [email protected]
Website: www.swsuk.co.uk
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innovation and achievement 2009energy and carbon saving
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Carbon saving and reduced energy consumption are key targets of the government’s sustainability objectives, which address the climate change challenge to deliver a cleaner, greener economy.
The government has produced consultations on the 2010 Part L for energy efficiency in buildings, the UK Low carbon Industrial Strategy, the UK Low Carbon Transition Plan and the UK Renewable Energy Strategy. Earlier in 2009 we had the consultation on the Heat and Energy Saving Strategy which looked at the existing stock and the drive towards zero carbon new buildings continues with the public and private funded Zero Carbon
Hub, in which the Association is a key player.The supply and cost of energy continues to present the industry with a difficult and uncertain future and manufacturers and suppliers have been at the forefront of developing new initiatives, both to minimise energy consumption and to use alternative sources of energy.
Through CPIA, the construction products industry demonstrates how it has addressed these challenges by managing the energy used in the manufacturing processes, as well as by manufacturing products that both reduce carbon emission and improve energy efficiency.
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innovation and achievement 200922 construction products association
innovation and achievement 2009energy and carbon saving
Marantec UK a division of Link Controls LtdMarantec blueline technology (currently available in Comfort 220.2 blueline)This extremely energy efficient door operating system uses
Marantec blueline technology with very low power consumption
in stand-by mode.
The system is based upon active sleep mode technology developed
by Marantec. All components are switched off in stand-by mode.
When the system receives an impulse in the sleep mode for
instance via hard transmitter, it immediately functions at 100%.
The system only requires a minimum energy consumption of 0.3 watt
to ensure operation, which equates to more than 90% of energy
savings, compared to other operator systems currently available.
The Blueline system guarantees permanent availability of all safety
and comfort functions. Marantec sets international standards for
energy efficiency and environmental saving.
What is innovative or new?
• Extremely energy efficient door operator system thanks to the lowest power consumption in stand-by mode by use of an intelligent microprocessor control
• Blueline is a patentable technology, it is trendsetting and technologically the most advanced system for doors available globally
How are benefits delivered?
90% energy saving potential compared with standard operators:
Stand-by consumption of a door operator with blueline technology
(Comfort 220.2 blueline) < 0.3 watt = 2.5 kWh per year;
Stand-by consumption of a standard operator about 4 watts
= 35 kWh per year
The only garage door operator designed specifically to save
running costs for the consumer
Contact details
Contact: Carl Hill
Address: Marantec UK
A Division of Link Controls
Stuart Road, Manor Park
Runcorn, Cheshire
WA7 1TS
Telephone: + 44 1928 53 08 26
Facsimile: + 44 1928 57 15 99
Email: [email protected]
Website: www.marantec.com
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innovation and achievement 2009 23construction products association
innovation and achievement 2009energy and carbon saving
The BSS Group plc Contractor Supply FacilityThe BSS Group plc has recently joined a legal entity partnership
called Construction Site Solutions (CSS) consisting of The BSS
Group plc, Speedy Hire plc, Lavendon Group plc and Hewden
(part of Finning International Inc). Together a new CSS on site
facility for contractors is currently being constructed, which
provides onsite workshops, offices, stores and a self-selection
trade counter area.
The unit reduces the carbon footprint of traditional short-term
accommodation by more than 50%. It is constructed in steel that
can be recycled and timber products from a sustainable source,
either PFC or PEFC. The unit is lined with pre-decorated
plasterboard made from 95% recycled products and offers fire
resistance as well as superior insulation properties.
In addition it boasts insulated doors and floors, waterless urinals,
water saving cisterns, T5 low energy light fittings, PIR sensors and
is powered by renewable energy sources, thus further reducing
energy consumption.
What is innovative or new?
The component products used to build the unit, combines the
expertise of the CSS companies to deliver the highest energy
and carbon savings possible. It offers market leading
improvements in insulation, lighting, water usage and provides
heating and electricity that offsets that being drawn from the
national grid.
How are benefits delivered?
The water conservation devices such as rain water harvesting,
have a dramatic impact on the water needed to run the unit;
on average each urinal will save 150,000 litres of water a year.
Other proposed products to be installed include solar
photovoltaic (PV) and heat pumps that will significantly reduce
running costs and the carbon footprint. Running cost reduction
is estimated to be more than 30% over a normal traditional
constructed accommodation.
Contact details
Contact: Alan Ball
Address: The BSS Group plc
Fleet House
Lee Circle
Leicester
LE1 3QQ
Telephone: 0116 262 3232
Facsimile: 0116 253 1343
Email: [email protected]
Website: www.bssgroup.com
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innovation and achievement 200924 construction products association
Halfen Ltd and Cityroofs LtdAquadyne Living WallA living facade which reduces the impact of solar gain upon a
structure. The solution employs lightweight supporting structures
designed by Halfen, a hydroponic irrigation system supplies
sufficient nutrients and water through the Aquadyne system to
support plant growth. Aquadyne is 100% recycled mixed polymer
plastics destined for landfill, acting as a capillary vessel allowing the
plant root zone to remain moist without being saturated.
The soil-less solution is designed to incorporate rainwater
harvesting, photovoltaics and possible edible food sources.
For every 20 Sqm of Aquadyne product used in construction,
independent research has proven that at least one tonne of CO2
will be saved from generation. This does not include the exchange
which happens through photosynthesis. The whole process
reduces the reliance on air conditioning, and hence reduces energy
consumption, CO2 generation and pollution.
What is innovative or new?
The redefining of recycled used polymers which are difficult
and un-economical to separate, designed to allow plant growth
whilst suspended vertically from the face of a structure.
How are benefits delivered?
The product protects a building structure from solar gain
thus allowing a reduction in the use of cooling systems and
therefore energy consumption and pollution generation.
The system also encourages the use of rainwater harvesting
and photovoltaics and introduces the possibility of an edible
wall within small living spaces.
Contact details
Contact: Matthew Hoddinott
Address: Imex Centre
Radway Green
Crewe
Cheshire
CW2 5PR
Telephone: 0800 328 7084
Email: [email protected]
Website: www.cityroofs.com www.halfen.co.uk
innovation and achievement 2009energy and carbon saving
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innovation and achievement 2009 25construction products association
Kingspan Insulation Limited Refurbishment of The Victorian House of the Future, CamdenThe process comprised the refurbishment of a solid walled Victorian
property in Camden to very high levels of energy efficiency.
There were conservation constraints which meant that external
insulation was not a feasible option. The low thermal conductivity
of Kingspan Kooltherm insulation products allowed internal
insulation to be used with minimal loss of living space, with most of
the walls in the house now achieving a U-value of just 0.19 W/m².K.
The rest of the house was insulated to a similarly high standard,
with the roof achieving a low U-value of 0.15 W/m².K.
Overall CO2 emissions have been reduced by 70%, as shown by
monitoring to date. This is a carbon dioxide emission level that
would allow it to achieve Level 4 of the Code for Sustainable
Homes. The project is being used for social housing and will be
monitored for energy consumption for five years.
What is innovative or new?
Close partnership working between contractor and
manufacturer enabled very high levels of energy efficiency to
be achieved in what was a difficult refurbishment.
The building is the first of its type to achieve carbon dioxide
emission levels that would allow it to achieve Level 4 of the
Code for Sustainable Homes.
How are benefits delivered?
The project will deliver great value to the construction industry.
It shows what partnership working can achieve. It also shows
that exemplary energy efficiency and carbon emissions can be
achieved even in the most difficult of housing refurbishment
projects. The data that will be collected will demonstrate what
has worked in practice – putting the standards to the test.
Contact details
Contact: Peter Morgan
Address: Kingspan Insulation Limited
Pembridge
Leominster
Herefordshire
HR6 9LA
Telephone: 01544 388 601
Facsimile: 01544 388 888
Email: [email protected]
Website: www.insulation.kingspan.co.uk
innovation and achievement 2009energy and carbon saving
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innovation and achievement 200926 construction products association
Baxi Group Baxi EcogenBaxi Ecogen is a wall-hung micro combined heat and power boiler
that uses a Free Piston Stirling Engine to generate 1kWh of
electricity while providing space heating and hot water. Baxi has
developed the technology specifically for domestic applications to
provide an appliance that operates virtually noise and vibration free,
in a case that is no bigger than a standard domestic boiler.
Intelligent controls reduce the flow temperature (heat output) to
match the property heat load requirements, therefore allowing
continuous operation on the unit, maximising electricity generation.
The boiler controls are removable and incorporate a
programmable room thermostat. Cylinder and outdoor
temperature sensor kits will also be available as optional
accessories. This allows close monitoring of room, hot water
and outdoor temperatures.
Baxi Ecogen continuously compares actual temperatures (room or
hot water) with desired temperatures (set points). If appropriate,
the boiler flow temperature can then be reduced.
What is innovative or new?
Unlike solar or wind powered technologies, Baxi Ecogen
operates at specific times of the day when the carbon intensity
of grid-provided electricity is at its worst. As this is technically
when the trading price of electricity is highest, the true carbon
savings of micro-CHP are greater than the average grid intensity.
How are benefits delivered?
Baxi Ecogen will help housebuilders to comply with the Code
for Sustainable Homes.
Energy generated close to the point of use is far more efficient
than that generated at a centralised power plant.
Householders will reduce their carbon footprint, save money
on fuel bills and be less dependent on the electricity network.
Any surplus generated may be sold back to the grid.
Contact details
Contact: Steve Rickards
Address: Baxi Group
Brooks House
Coventry Road
Warwick
CV34 4LL
Telephone: 08448 711538
Facsimile: 08448 711537
Email: [email protected]
Website: www.baxiecogen.com
innovation and achievement 2009energy and carbon saving
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innovation and achievement 2009 27construction products association
Permanite Engineered Roofing SystemsPermaTEC EcoWRAPPermaTEC EcoWRAP is a hot applied waterproofing compound which
is manufactured from a specially formulated combination of refined
bitumen, synthetic rubbers, fillers and other additives. It is suitable for
use as the waterproofing layer on most flat roofing systems when
covered by suitable protection or when used in an inverted roof or
green roof specification. It is also suitable for use as a damp-proof
membrane in solid concrete floors or as the waterproofing layer in a
typical sandwich membrane used for above or below ground
waterproofing in concrete, brick or blockwork structures.
PermaTEC EcoWRAP is the first hot melt waterproofing system to
be manufactured with ‘zero wrapper waste’. The compound is
encapsulated in a thin film which blends into the material when
heated. PermaTEC EcoWRAP is the most environmentally friendly
hot melt system in the world.
What is innovative or new?
PermaTEC EcoWRAP compound features easy flow melt
technology which means it is ready for use at a temperature of
150oC – 160oC compared with the usual 200oC for competing
systems. This saves preparation time and significantly reduces
energy consumption on-site. Furthermore, no outer packaging
is required which means 98.5% less waste than equivalent
cardboard-packaged products.
How are benefits delivered?
EcoWRAP is the only hot melt product to be manufactured in
the UK, which means its delivery has a dramatically smaller
carbon footprint than competing products which are typically
imported from the North American continent. We deliver
direct from factory to the site in one operation. The product
generates 98.5% less waste than competing systems, reducing
on-site waste and disposal costs. PermaTEC EcoWRAP helps
to improve working conditions on site with its easier to
handle 12kg kegs.
Contact details
Contact: Nichola Clayton
Address: IKO PLC
Appley Lane North
Appley Bridge
Wigan
Lancashire
WN6 9AB
Telephone: 01257 256097
Facsimile: 01257 252514
Email: [email protected]
Website: www.permanite.com
innovation and achievement 2009energy and carbon saving
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innovation and achievement 200928 construction products association
innovation and achievement 2009energy and carbon saving
Aggregate Industries UKLow Temperature AsphaltAggregate Industries has worked in Partnership with The Mercia
materials engineering group to develop a process for mixing Asphalt
at temperatures of between 70°C and 90°C. The objective to
provide a CO2/tonne value better than a cold mix asphalt using
bitumen emulsion and better than traditional Hot Mix asphalt.
The resulting material was required to retain similar performance in
compaction, trafficking and engineering performance compared to
a similar hot mix asphalt product. This was to be on the basis of
using traditional asphalt plants, delivery vehicles, binders and laying
equipment currently used by the asphalt industry.
The trial sites for Shropshire County Council at Market Drayton
identified the following benefits:• Nil Fuming
• Nil Aging
• Ease of compaction
• Fatigue enhanced
What is innovative or new?
Asphalt Concretes can be mixed at half the temperature of
traditional asphalt whilst using the same mixing plant, delivery
vehicles, binders and laying equipment.
How are benefits delivered?
Reduced fuel usage in manufacturing at lower temperatures
reduces CO2/tonne generated. The binder does not age due to
less heat, it also does not fume which is a Health and Safety
benefit to the surfacing gangs.
Contact details
Contact: Tom Bateson
Address: Aggregate Industries
Brookside House
Bardon Hill Road
Coalville
Leicestershire
LE67 1TD
Telephone: 01530 512140
Facsimile: 01530 249542
Email: [email protected]
Website: www.aggregate.com
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innovation and achievement 2009 29construction products association
innovation and achievement 2009energy and carbon saving
Aggregate Industries UK Urban Surface Protection used on Charcon StoneMasterStoneMaster is a paving product which replicates Yorkstone and
was chosen to be treated with Urban Surface Protection.
USP is a fluro-polymer that impregnates the paving surface, forming
a barrier preventing stains from penetrating the material. Rain or
regular cleaning will remove most staining, including chewing gum,
normally requiring a major ‘deep clean’ of the product.
USP is the first coating to be applied on line in a factory environment,
instead of once the product has been laid.
For a city centre, the size of Liverpool, (30,000 sq metres), up to six
deep cleans a year are required including chewing gum removal at
£1.50 per sq metre. This can cost up to £23.40 per sq metre.
StoneMaster paving with pre-applied USP could reduce the number
of cleans from six to two, giving maintenance costs of £4.20 per sq
metre per year. The saving on cleaning costs and detergents would
be in the region of £576,000 per year.
What is innovative or new?
Charcon is the first paving manufacturer to offer this innovation.
The formula has been enhanced to be effective on paving.
The new innovation includes applying the product on-line in a factory
to make sure that the product is uniformly applied to give
a consistent dosing and level of performance.
How are benefits delivered?
There is a major cost saving in terms of the amount of cleaning
that has to be carried out on StoneMaster with USP pre-applied.
The cost savings can be substantial.
The use of detergents with the potential to have negative impacts
on the environment is also minimised.
Transferring the application of the product on-line within
a factory saves substantial amounts of product as any overspray
is recycled.
Contact details
Contact: Paul Wagstaff
Address: Aggregate Industries Marketing
Brookside House
Bardon Hill
Leicestershire
LE67 1TD
Telephone: 01530 512366
Facsimile: 01530 249542
Email: [email protected]
Website: www.charcon.com
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innovation and achievement 200930 construction products association
innovation and achievement 2009energy and carbon saving
Baxi Group Multifit GasSaverThe Multifit GasSaver is an innovative low cost product that sits
neatly between boiler and flue and recycles flue gas heat which
would normally be expelled into the atmosphere and wasted.
It creates a thermal store of condensate from the waste flue gases.
Heat from this condensate store is then used to pre-heat water
coming into the boiler from the cold mains supply, significantly
reducing the amount of gas required by the boiler to heat the water.
This means lower energy bills for the householder and greater
carbon savings.
What is innovative or new?
Multifit GasSaver increases boiler efficiency, saving up to 37 % of
the gas used to heat hot water annually, according to tests
conducted by an independent scientific test house. The calculation
is based on an average household’s consumption of 100 litres of
hot water per day.
How are benefits delivered?
By selecting the GasSaver in conjunction with other low-cost
measures, the cost of achieving Code Level 3 can be minimised.
It has been proven by independent testing to achieve domestic
hot water savings of up to 6%.
It is an easy to install low carbon solution, offering up to 700kg
carbon emissions saving compared to an SE boiler, according to
independent tests carried out by TUV NEL (2008).
With no controls, settings or moving parts, it is maintenance
free and does not require servicing.
Contact details
Contact: Steve Rickards
Address: Baxi Group
Brooks House
Coventry Road
Warwick
CV34 4LL
Telephone: 08448 711538
Facsimile: 08448 711537
Email: [email protected]
Website: www.baxigroup.com/uk
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innovation and achievement 2009 31construction products association
innovation and achievement 2009energy and carbon saving
Celotex Celotex FR4000 and CG4000By utilising groundbreaking technology, Celotex has achieved
complete Class O fire performance within two of its most recent
product introductions. FR4000 and CG4000 represent the most
cost effective, thermally efficient fire performance PIR insulation
boards available on the market today.
FR4000 and CG4000 offer Class O fire performance throughout
the entire product - not just the foam core. An improved lambda
value of 0.022W/mK allows for up to 5mm less product to be used
in some applications. Specifically targeted at pitched roof and wall
applications, FR4000 is available in a range of thicknesses from
25mm – 150mm. CG4000 is suitable for partial fill cavity wall
applications and is available from 40mm – 80mm.
Since its launch, both products have seen an excellent uptake within
the thermal insulation market helping to lower CO2 emissions from
the building fabric whilst meeting legislative frameworks such as Part
L, BREEAM and the Code for Sustainable Homes.
What is innovative or new?
FR4000 represents the only PIR insulation product with Class O
fire performing properties as well as an improved thermal
performance of 0.022W/mK. This level of performance is
achieved throughout the entire product – not just the foam
core. This provides a unique position to Celotex within the PIR
thermal insulation market.
How are benefits delivered?
FR4000 and CG4000 enable premium fire performance to be
achieved across any applications that demand Class O fire
performance. Combining its improved thermal performance
and low emissivity foil facers can result in some applications
requiring less product; thereby saving money and space.
Available in thicknesses up to and including 150mm eliminates
the requirement for two layer systems helping to save labour
costs and installation times.
Contact details
Address: Celotex Limited
Lady Lane Industrial Estate
Hadleigh
Suffolk
IP7 6BA
Telephone: 01473 822093
Email: [email protected]
Website: www.celotex.co.uk
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innovation and achievement 200932 construction products association
innovation and achievement 2009energy and carbon saving
Freerain Limited G-TanksFreerain is a specialist rainwater harvesting company that accounts
for around 10% of the UK market.
At the heart of rainwater harvesting systems is a storage tank, many
of which are imported into the UK from the more mature German
market; the transport element of this supply-chain arrangement
leads to an excessive carbon footprint.
To overcome this disadvantage, Freerain has invested in an innovative
range of moulds to produce a range of rotationally moulded
storage tanks in the UK, principally for the UK market. However, as
the balance of trade between mainland Europe and the UK is
east-to-west, empty backload opportunities will also be taken to
export the tanks.
The tanks have been scientifically designed to achieve the maximum
ratio of strength to weight (of raw materials used) and to provide
a lower profile, hence the depth of excavation, compared to that
required for conventional barrel-shaped tanks, is less.
What is innovative or new?
The innovative features of this product are its manufacture in the UK,
its scientific high strength/weight ratio design and its high volume,
low height ratio.
How are benefits delivered?
This product obviates the environmentally unfriendly practice of
transporting such tanks from Germany into the UK market;
quite apart from the carbon footprint savings this achieves, it also
lowers the price of the product to the consumer by around
one-third.
The low profile of the product also addresses site-related
installation constraints, such as the need for excessively deep
excavation. The products design strength also does away with
the need to surround the tank with a concrete backfill which is
a usual requirement for glass fibre tanks.
Contact details
Contact: Terry Nash
Address: Millennium Green Business Centre
Rio Drive
Collingham
Newark
Notts
NG23 7NB
Telephone: 01636-894900
Facsimile: 01636-894909
Email: [email protected]
Website: www.freerain.co.uk
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innovation and achievement 2009 33construction products association
innovation and achievement 2009energy and carbon saving
Hanson UK Frindsbury Wharf marine sand and gravel processing plantHanson’s replacement marine sand and gravel processing plant at
Frindsbury Wharf near Rochester was designed to significantly
reduce energy and save carbon.
The old plant was fed by a loading shovel which carried materials to
be processed 120 metres to the plant feed hopper. Crushing of
larger sizes to make saleable products took place in campaign
crushing by mobile equipment. This meant that materials were first
processed then stored, crushed and then processed again. The
new plant eliminates all double handling.
What is innovative or new?
The feed hopper was moved close to the ship discharge point,
reducing fuel consumption by 28% and increasing throughput by
a factor of 2.5. The mobile diesel powered crusher was replaced
by two in-line Sandvik H3800 cone crushers controlled by
an innovative PLC control. The crusher is automatically powered
down when not needed.
How are benefits delivered?
The loading shovel uses 65,000 litres less fuel a year with a carbon
reduction of 174 tonnes. Eliminating the mobile crushing
equipment gives further fuel savings of 75,000 litres with a carbon
reduction of 200 tonnes a year.
Automated control of the two in-line crushers enables power
saving of 132,000 kW a year with a carbon reduction of 71 tonnes.
The plant also features a sand recovery system incorporating
a full water recycling plant to eliminate waste.
Contact details
Contact: Dave Brown
Address: 20 20 Industrial Estate
Allington
Maidstone
Kent
ME16 0LQ
Telephone: 01622 679461
Facsimile: 01622 679558
Email: [email protected]
Website: www.hanson.com/uk
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innovation and achievement 200934 construction products association
innovation and achievement 2009energy and carbon saving
Kingspan Insulated PanelsKingspan WoodTherm™
Kingspan WoodTherm™ combines an insulated panel system with
a natural wood veneer façade, offering high thermal performance
with design flexibility.
It is available in six different natural woodgrain finishes, from light
tones akin to pine through to richer shades, ensuring a versatile way
to enhance visual impact. Underneath the attractive façade lies a
high performance insulated panel, with factory formed jointing to
ensure a low air leakage rating and a PIR ECOsafe low GWP
insulating core that can achieve U-values as low as 0.23
W/m2K.
The product can only be installed as a secret fix system which
allows a smooth façade with all panel fasteners hidden from view.
It is also easily integrated with other elements such as doors,
windows, brickwork or stonework, offering an ideal solution for
everything from apartments or offices, to retail, educational and
health projects, and is suitable for refurbishment as well as new build.
What is innovative or new?
These are real wood veneers sourced from sustainable forests
giving a natural variation of grain, as opposed to the repetitive
patterning common in products that use photographic
representations of timber. The clear design benefits are
combined with high levels of thermal performance.
How are benefits delivered?
Kingspan WoodTherm™ is available with the Kingspan Total
Guarantee for structural and thermal performance, and has
undergone a series of independent durability and weathering
tests to recognised industry standards. The system is cost
effective, easy to maintain, graffiti-proof and has a ten year
colourfast guarantee.
The system is also easy to install, with minimal training needed.
Installation times are greatly reduced compared to some other
cladding solutions, allowing a weatherproof envelope to be
quickly formed.
Contact details
Contact: Claire Maskell
Address: Kingspan Insulated Panels
Greenfield Business Pk2
Holywell
Flintshire
CH8 7GJ
Telephone: 01352 717251
Facsimile: 01352 716199
Email: [email protected]
Website: http://www.kingspanpanels.com/Home.aspx
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innovation and achievement 2009 35construction products association
innovation and achievement 2009energy and carbon saving
Knauf Insulation Mineral Wool with ECOSE® TechnologyKnauf Insulation glass and rock mineral wool made with ECOSE®
Technology doesn’t look or feel like other insulation. The natural
brown colour represents a level of sustainability and handling never
before achieved, combined with the same reliable thermal, acoustic
and fire performance expected from mineral wool and resulting in
the next generation of mineral wool.
The brown colour and ‘super soft’ feel comes from ECOSE®
Technology, a revolutionary, new, natural, formaldehyde-free binder
technology, made from rapidly renewable bio-based materials
instead of oil based chemicals.
Products made with ECOSE® Technology are more sustainable,
as they have the added benefit of using a natural binder, which is up to
70% less energy intensive than traditional binders.
With ECOSE® Technology, rapidly-renewable bio-based materials
replace the traditional chemicals to create more advanced and
sustainable products, helping to reduce carbon footprint even further.
What is innovative or new?
ECOSE® Technology, a revolutionary, new sustainable binder
born from five years of intensive research. ECOSE® Technology
binder is the first ever bio-based binder, based on natural,
rapidly renewable ingredients rather than petroleum based
substances, widely applicable to mineral wool. ECOSE®
Technology reduces binder embodied energy by up to 70%.
How are benefits delivered?
With the trend towards environmentally responsible and
‘formaldehyde free’ specifications, Knauf Insulation products
with ECOSE® Technology build on the already exceptional
environmental credentials of mineral wool. Knauf Insulation’s
new ECOSE® Technology ensures products do not contain
artificial colours or added formaldehyde, resulting in environmental
credentials above our already A+ rated products in the Green
Guide. Embodied energy for the binder is reduced by 70% and
plant emissions during the production of mineral wool also reduced.
Contact details
Contact: Knauf Insulation
Address: PO BOX 10
Stafford Road
St. Helens
Merseyside.
WA10 3NS
Telephone: 08700 668660
Facsimile: 0870 400 5797
Email: [email protected]
Website: www.knaufinsulation.co.uk
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innovation and achievement 200936 construction products association
innovation and achievement 2009energy and carbon saving
Polypipe VentilationThe Domus Fresh Air Supply SetThe Domus Fresh Air Supply Set has been designed specifically to
meet the growing need for the managed provision of replacement air
ensuring that comfortable indoor air quality is maintained in properties
when Exhaust Air Heat Pumps are installed. They are designed for
installation without over ventilating, preventing energy waste.
The design promotes draught-free fresh air back into the property
through an unobtrusive multi-directional inlet grille that includes
a washable environment filter which cleanses incoming air.
Externally, there is a choice of four outlet colours for outside
brickwork matching, ensuring that the installation is as discreet as
possible. It is suitable for walls up to 450mm thick and is easy and
quick to install.
To assist with building pressure, tests as required by Approved
Document L, a bespoke blanking commissioning plug has been
included for the installer’s convenience. This is a necessity when
using energy efficient exhaust air heat pumps.
What is innovative or new?
• Allows set rate of fresh air into the building
• Filters incoming air
• Limited flow rate and multi-directional diffuser prevent draughts
• Discreet air inlet
• Air flow characteristics of the kit verified by the University of Cambridge ensuring guaranteed end-to-end system performance and appliance compatibility
How are benefits delivered?
Exhaust Air Heat Pumps provide energy efficient central heating
and hot water by extracting heat from waste inside air.
The Domus Fresh Air Supply Set ensures Exhaust Air Heat Pumps
function effectively by supplying exactly the right amount of
replacement fresh air to the building.
Unlike standard ventilation, it filters air and ensures a set rate of
air passes into the building.
Contact details
Contact: Chris Atkinson
Address: Polypipe Ventilation
Bearwalden Business Park
Royston Road
Wendon Ambro
Saffron Walden
Essex
CB11 4JX
Telephone: 01799 540602
Facsimile: 01799 541143
Email: [email protected]
Website: www.polypipe.com
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innovation and achievement 2009 37construction products association
innovation and achievement 2009energy and carbon saving
Senior Architectural Systems Ltd Hybrid Timber/Aluminium Fenestration SystemSenior Hybrid Systems is a timber/aluminium fenestration
(windows, doors and curtain wall ) product range, available through
a network of locally based fabricators, that has been developed to
meet the new building regulations and environmental standards.
Local fabrication reduces site lead times and overall carbon
footprint.
All timber is laminated and from PEFC accredited sources.
Aluminium is fully recyclable.
Product is designed to be sustainable in its procurement,
manufacture and service life. At the end of the life-cycle all
components (aluminium, timber, glass and steel ) are fully recyclable.
Product is tested to latest UK and European performance standards.
What is innovative or new?
The system is unique in it’s manufacturing process. The window
profiles are delivered to the window fabricator in pre-finished
bar lengths of timber and aluminium. The manufacturing
process is similar to that used for manufacturing aluminium or
PVC windows ensuring that local manufacturing resources can
be used and transport minimised. Currently windows of this
type are imported as finished products increasing carbon output,
decreasing site efficiency and reducing local employment.
How are benefits delivered?
Local manufacturing means that the normal supply chain can
be used. Also stocks held in the UK mean reduced lead times
and transport.
The ability to manufacture locally allows site measurement and
the system therefore lends itself to upgrading of existing building
stock to higher insulation standards.
Contact details
Contact: Lennart Jonsson
Address: Eland Road
Denaby Main
Doncaster
DN12 4HA
Telephone: 01709 772600
Facsimile: 01709 772601
Email: [email protected]
Website: www.seniorarchitectural.co.uk
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innovation and achievement 200938 construction products association
innovation and achievement 2009energy and carbon saving
SIG InsulationsInsulslab SFRC (Steel Fibre Reinforced Concrete)Insulslab SFRC (Steel Fibre Reinforced Concrete) is a completely
unique (and patented) waffle shaped raft foundation which provides
significant benefits over traditional methods of construction for
both commercial and residential developments.
Insulslab SFRC is formed by connecting interlocking Insulslab pods,
as detailed in a structural engineer’s general arrangement drawing,
and then pouring Steel Fibre Reinforced Concrete (SFRC) over
the top to form a substantially rigid waffle shaped slab.
The Insulslab pods are made out of extremely strong expanded
polystyrene (EPS) in order to sustain the compressive forces
involved. The pods interlock to aid placement and help reduce
any risk of vertical or lateral movement when the concrete is placed.
The interlocking pods not only act as a void former but also
provide a substantial thermal performance without the need for
a screed because the insulation is incorporated into the main
construction of the foundation.
What is innovative or new?
Insulslab SFRC is a new, unique method for foundation
construction and provides the building with a super insulated
foundation over its lifetime.
A typical u value of around 0.11 W/m2K can be achieved for
a detached domestic building with a perimeter divided by area
(P/A) ratio of 0.48.
How are benefits delivered?
Insulslab SFRC delivers significant benefits in two key areas
• Time/cost saving and minimal environmental impact in construction
• Outstanding thermal insulation performance over the lifetime of the building
This means the builder benefits from the speed of construction
– minimal groundwork, less concrete, less site traffic and waste
and when the building is constructed the owner/occupier
benefits from continuing thermal performance over its lifetime
delivering real energy and carbon savings.
Contact details
Contact: Mark Gray
Address: SIG Insulations
Hillsborough Works
Langsett Road
Sheffield
S6 2LW
Telephone: 07764 906384
Email: [email protected]
Website: www.insulslab.com
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innovation and achievement 2009 39construction products association
innovation and achievement 2009energy and carbon saving
SupaWall LimitedSupaWall®, SupaRoof® and SupaFloor™ PanelsSupaWall® is a patented high performance closed panel timber
frame building system that is one of the most advanced timber
frame systems in the world. SupaWall®, SupaRoof® and SupaFloor™
have been developed to provide the complete building envelope
with this world class performance. The SupaWall System® may also
be used for refurbishment projects and infill panels in other framed
building structures.
This British invention is a significant advance on the traditional open
panel products currently in use. It is covered by patents GB2415714
and GB2436989 and has been awarded a British Board of Agrément
Certificate No. 09-4659 and can be licensed worldwide.
The system can be used with any form of interior and exterior
cladding, making it very flexible in terms of architecture and usage.
A three bedroom bungalow was recently erected so that it was
wind and watertight in less than two hours with factory fitted
windows and doors.
What is innovative or new?
SupaWall® is a closed timber frame panel system for walls, floors
and roofs. Its innovative combination of layers with factory
injected insulation provides excellent thermal performance.
It benefits from a patented male to female panel joining system
that simplifies site assembly and gives excellent air permeability.
How are benefits delivered?
The SupaWall System® manufactured off-site, with a u-value
better than 0.12 W/m2K tested by the National Physical
Laboratory, minimises thermal bridging (y-value of 0.04 W/m2K)
and delivers air permeability to 1 m3/m2h@50pa.
The environmentally friendly polyurethane foam insulation has
been specially developed to have an ODP of zero, a GWP of 1
and be CFC, HCFC and HFC free. SupaWall® dramatically
reduces site construction time and provides a high quality
building envelope.
Contact details
Contact: Bryan Woodley
Address: SupaWall Limited
Tarnacre Hall Business Park
Tarnacre Lane
St. Michaels
Preston
PR3 0SZ
Telephone: 07879 680756
Facsimile: 01995 679769
Email: [email protected]
Website: www.supawall.com
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innovation and achievement 200940 construction products association
innovation and achievement 2009energy and carbon saving
Kingspan Insulated Panels Kingspan Render PanelKingspan Render Panel is a composite insulated panel system with a
pre-rendered finish giving the appearance of traditional rendered
blockwork. An innovative joint gasket minimises the visual impact
of the joint and ensures that the product can be installed smoothly
to integrate with the building design without compromising weather
proofing, thermal performance or air permeability.
The render finish is applied off-site under controlled factory
conditions, which removes reliance on additional wet trades to give
a number of key advantages. One is that consistency in colour and
flatness is maintained to higher levels than may be found with
traditional on-site application techniques, where human error and
changes in weather can lead to problems.
Currently, Kingspan Render Panel is available in thicknesses up to
100mm. This will provide a U-value of around 0.23 W/m2K and
an air leakage rate of 5m3/hr/m2 or better, well within current
government standards.
What is innovative or new?
The product combines the advantages of a modern, thermally
effective, fast track system with the aesthetics of a traditional
appearance. It provides a factory controlled quality finish,
and removes the element of weather dependency from projects.
How are benefits delivered?
A more predictable construction schedule is made possible,
as a weather proof envelope is formed once installation is
complete to allow quicker onset of dependent internal work.
Furthermore, the lack of other trades means single-point
responsibility for the whole system.
At the centre of the system is an ECOsafe PIR core which offers
low GWP, excellent thermal efficiency and compliance with
current Building Regulations, backed by the Kingspan Total
Guarantee, offering thermal and structural performance.
Contact details
Contact: Claire Maskell
Address: Kingspan Insulated Panels
Greenfield Business Pk2
Holywell
Flintshire
CH8 7GJ
Telephone: 01352 717251
Facsimile: 01352 716199
Email: [email protected]
Website: http://www.kingspanpanels.com/Home.aspx
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innovation and achievement 2009 41construction products association
innovation and achievement 2009energy and carbon saving
Kingspan Insulated Panels Kingspan Thermatallic®
Kingspan Thermatallic® combines all the benefits of insulated panel
construction with the flatness and attractiveness of
an Aluminium Composite Material (ACM) façade.
It provides a high level of flatness and stability, and is available in
a range of cassette sizes and brilliant colours. It is extremely
weatherproof, impact resistant, break-proof and vibration damping,
and is suitable for both refurbishment and new build projects.
Factory formed jointing and a PIR ECOsafe low GWP insulation
core can achieve U-values as low as 0.23 W/m2K. Key benefits
include single point responsibility for installation of the entire wall;
reducing the need for specialist contractors and speeding build time
in comparison with traditional façade systems.
The product is approved by the Loss Prevention Certification
Board (LPCB) and fully tested to CWCT standards. It is fibre-free,
removing the risk of loose fibres being released and compromising
hygiene standards.
What is innovative or new?
The product combines the aesthetics of a metal façade with
the performance of composite panels. Faster installation means
a weatherproof envelope can be quickly built, leading to internal
trades getting onsite sooner and further savings in time.
Guaranteed excellent thermal performance and low air leakage
rates are easily achieved.
How are benefits delivered?
• Design flexibility
• Single point responsibility
• Fast installation, allowing other services to gain access sooner
• Removes metal façade from the critical path
• Property & Business Protection - LPCB LPS 1181 Grade EXT-B certified insurer approved
• Environmentally sustainable PIR insulation core, low GWP and non-deleterious
• Full system available with the Kingspan Total Guarantee, covering thermal and structural performance
• Simple detailing maximises air leakage performance
Contact details
Contact: Claire Maskell
Address: Kingspan Insulated Panels
Greenfield Business Pk2
Holywell
Flintshire
CH8 7GJ
Telephone: 01352 717251
Facsimile: 01352 716199
Email: [email protected]
Website: www.kingspanpanels.com/Home.aspx
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innovation and achievement 200942 construction products association
innovation and achievement 2009energy and carbon saving
EDGETECH IG INC Super Spacer® TriSeal™ Premium Super Spacer TriSeal Premium is the latest development in
Edgetech’s Warm Edge Technology spacer product range.
Designed to replace the traditional aluminium strip that sits
between two panes of glass in a window, it is the next generation
flexible, silicone foam warm edge spacer system designed to satisfy
the toughest commercial glazing demands, including silicone
structural glazing (SSG). A polyisobutylene primary seal is required
for enhanced gas retention and low moisture vapor transmission,
plus a silicone seal for proven structural performance.
TriSeal Premium maintains excellent flexibility at low temperatures,
has outstanding resistance to high heat and has a low compression
set. The product has been specifically developed with the important
British Fenestration Ratings Council window energy rating scheme
in mind, to provide the best possible performance.
What is innovative or new?
The manufacturing procedure to make TriSeal Premium is
completely unique. Edgetech has developed the processes to
ensure the product has outstanding thermal conductivity.
It offers an improvement in thermal conductivity over and above
other Warm Edge products of 50%.
How are benefits delivered?
In two words: energy efficiency. The cost effective TriSeal
Premium improves thermal performance of the overall window
significantly. The internal edge of the glazing is up to 65% warmer.
The product also provides durability and offers a reduction in
condensation by up to 70% compared with conventional sealed
units and improved noise reduction of up to two decibels.
When the product is applied by Edgetech’s customers it also
provides the benefit of improved productivity.
Contact details
Contact: Andy Jones
Managing Director
Address: Edgetech IG Inc
Stonebridge House
Rowley Drive
Stonebridge Trading Estate
Coventry
CV3 4FG
Telephone: 08700 566 844
Facsimile: 02476 639 727
Email: [email protected]
Website: www.superspacer.co.uk
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innovation and achievement 2009improvements in site efficiency
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The construction industry is constantly looking for ways to deliver the completed building or construction project in shorter time, by using fewer resources and offering better value for money. Improving site efficiency is a key part of this.
Certainly manufacturers who can show that their products will help improve efficiency have an added opportunity to gain a competitive edge.
With improvements in site efficiency the industry has delivered a range of solutions that have responded to the need for best value rather than lowest price. Driven by market forces these improvements can reduce the need for regulation, but also encourage clients and specifiers to procure best value products.
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innovation and achievement 200945 construction products association
IBP Conex Ltd.Conex Push-FitThe Conex Push-Fit range of dezincification-resistant brass
plumbing fittings is the perfect solution for flame-free jointing.
Suitable for a wide variety of applications, Conex Push-Fit connects
with multiple tube types - including copper, stainless steel, carbon
steel and plastics (PB and PE-X).
The push-fit range is quick and easy to install - just five seconds for
a secure, leak-free joint. A specially designed grab ring ensures the
fitting is firmly secured but not fixed allowing for system alignment.
The fitting can also be demounted using a professional release tool
and reused up to 20 times. Conex Push-Fit also allows for
electrical continuity.
The new system can be used for hot and cold potable water,
heating, and chilled water systems. Its ease of installation and its
simple, robust design makes it the obvious choice for installers.
Conex Push-Fit is approved by WRAS and the Irish Board of
Agrément with DVGW pending.
What is innovative or new?
Conex Push-Fit fittings are revolutionary; they connect with
multiple tubes including copper, carbon steel, stainless steel, PB
and PE-X. The fittings are sustainable; they are demountable
with a professional release tool and can be re-used up to 20
times. They are manufactured from recycled material and can
be recycled at their life end.
How are benefits delivered?
Conex Push-Fit fittings reduce the number of fitting types
required as it can connect with multiple tube types including a
number of metallic and plastic pipes. The fittings are quick to
install saving considerable time compared to other fitting
methods and have a reduced risk due to being flame free.
Conex Push-Fit fittings are also demountable and re-useable.
Once the fitting is connected it is secure but not fixed allowing
for system alignment.
Contact details
Contact: Claire Binney
Address: IBP Conex Ltd.
Whitehall Road
Tipton
West Midlands
DY4 7JU
Telephone: +44 (0)121 557 2831
Facsimile: +44 (0)121 520 8778
Email: [email protected]
Website: www.ibpconex.co.uk
innovation and achievement 2009improvements in site efficiency
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innovation and achievement 2009 46construction products association
Hilti (Gt Britain) Limited Hilti X-HS-W wire hanger systemHilti X-HS-W wire is a combination of two innovations, Wire
Supports and Direct Fastening. The Hilti Wire Hanger can be
installed from floor level without any need to drill into the base
material. A “Hilti Grip” is used to lock the wire in both directions.
The product can be used to support rectangular or spiral
ventilation duct, electrical basket, lighting and other electrical
services. Hilti Wire substitutes traditional installation channels
and threaded drop rods used for these applications.
The Hilti Direct Fastening system is used to fix into concrete or
steel base material. The nail fastening element is applied with the
Hilti Cartridge Tool. The tool is mounted onto a Pole Accessory
to enable the operative to fix from the floor.
What is innovative or new?
The fixing element of the product requires no drilling and the
Pole Accessory enables setting out and fastening from the floor
thus reducing the need for mobile scaffolds or steps. There is
no other single wire system which offers these system benefits.
How are benefits delivered?
Productivity – Three times faster to install than traditional
installation methods (mechanical anchors, threaded drop rods
and installation channels).
Sustainability – Eliminating traditional installation methods
wherever possible in the installation of ventilation ducts and
electrical containment and we can reduce the weight/quantity of
steel installed on a project for these applications by up to 93%.
Health and Safety – Firstly eliminating traditional installation
material will reduce the need for metal cutting on site.
Secondly the Hilti Pole Accessory means setting out and the
fixing of Hilti Wire can be installed from floor level reducing
the need to work at height. Finally drill and fix is replaced by
Direct Fastening, this reduces the operatives exposure to
hand arm vibration.
Contact details
Contact: Peter Reynolds / Eddie Mills
Address: 1 Trafford Wharf Road
Manchester
M17 1BY
Telephone: 01618861433 / 1428
Email: [email protected]
Website: www.hilti.com
innovation and achievement 2009improvements in site efficiency
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innovation and achievement 200947 construction products association
innovation and achievement 2009improvements in site efficiency
Laidlaw Solutions Limited Laidlaw Orbis Integra Doorsets RangeThe range comprises a combination of steel frames and timber
doors. Supplied on-site fully protected with all non-projecting
ironmongery pre-fitted, the integrated package includes door,
frame, seals, glazing and ironmongery.
The co-ordinated package by Laidlaw minimises on-site disruption
and our systems ensure total compatibility of sizes, materials and
performance. The range is ideally suited to new build applications
which require a cost effective and durable solution, typically on
Design and Build, student and MOD accommodation, nursing
homes and hotels.
The steel frame is supplied in sections which lock together during
installation. Internal clamps within the frame are tightened to
complete the assembly. Lift-off hinges are factory fitted to the
frame and door allowing the door to be simply slotted into place,
requiring only final fitting of the door furniture. This rapid process
makes the Orbis Integra Doorset a highly economical and practical
solution and produces a quality finished installation.
What is innovative or new?
The frame system requires no time consuming pre-assembly.
Simply by slotting together the interlocking frame sections
around the wall, the frame is held in place permanently by a
series of patented internal clamps which lock the frame around
the wall structure.
How are benefits delivered?
• Installation time dramatically reduced by up to 75% compared to conventional timber or steel doorsets
• Reduced site-work and co-ordination
• Meets requirements of Building Regulations Approved Document M
• Meets requirements of MMC (Modern Methods of Construction)
• Complete scheduling service – doors, frames and ironmongery from a single source
• Ten year guarantee
• Factory fitted ironmongery
• Factory fitted glazing
• Fully Certified
Contact details
Contact: Nigel Bligh
Address: Laidlaw Solutions Limited
Unit 1 Brannam Crescent
Roundswell Business Park (West)
Barnstaple
North Devon
EX31 3TD
Telephone: 07968 861560
Facsimile: 01237 424602
Email: [email protected]
Website: www.laidlaw.net
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innovation and achievement 2009 48construction products association
innovation and achievement 2009improvements in site efficiency
Lafarge Readymix Integrated onboard slump process control systemConcrete production is relatively simple, but has always been a
problem of water - too much, too little. It all makes a difference
and can lead to waste, poor quality control, misconceptions and
arguments, not to mention dangerous practices.
A solution has been found by Lafarge - a fully integrated onboard
slump process control system - by allowing interface between all
aspects of the batching and delivery process the right mix is
delivered every time.
Most importantly this system ensures no human intervention is
involved, allowing for much improved health and safety practices
and the reduction of raw materials involved, including a major
reduction in excess water added to concrete on site.
What is innovative or new?
The product is new to the UK and Europe. Using this technology
in line with other technologies used by the company leads to the
re-education both of internal and external customers.
This process allows for the batching of the concrete to be seen in
a new light, taking an age old industry problem and improving on
it. Reducing costs, cement content and CO2 emissions and a
major reduction in water usage.
How are benefits delivered?
By batching correctly and reducing the need for drivers and
employees to climb up the back of trucks to check the concrete
in the truck, there is an obvious health and safety benefit.
Using technology to show customers facts about slumps rather
than perceptions, the correct specs are being met allowing a
reduction in raw materials.
Having reduced the need for water to be added on site, in
excess of ten million litres of water was added in 2007 – by
reducing this a saving of circa nine million litres have been saved
– enough to fill 3.6 Olympic size swimming pools.
Contact details
Contact: Stuart Rose
Address: Granite House
Watermead Business Park
Syston
Leicestershire
LE7 1PF
Telephone: 07734 743045
Email: [email protected]
Website: www.lafarge-aggregates.co.uk
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innovation and achievement 200949 construction products association
Hanson Building Products Hanson Quick Build™ Prefabricated clay brickwork masonry as part of flood defence systemHanson QuickBuild prefabricated masonry walling systems;
Walls may be single or double skin(cavity) with or without
insulation and are manufactured from clay brick, aggregate block,
aircrete block or natural stone. Panels may be up to 9m long x
2.5m high.
As used in a flood defence system, the panels are a permanent
shuttering to accommodate an in-situ concrete, poured against a
steel sheet piling system, which provides the main flood resistance
component. This technique eliminates the need for in-situ
bricklaying processes and so significantly reduces on-site
construction time and environmental impact. Consistently high
quality and improved site safety are achieved.
What is innovative or new?
The system provides prefabricated masonry panels which are
of similar properties to traditionally built masonry but with
superior structural performance.
The system takes a very traditional material and utilises it in a
prefabricated component eliminating all of the problems
associated with site construction such as quality consistency,
speed and improved safety.
How are benefits delivered?
• Sustainably produced and transported structural components with a quality finish
• Increased safety through reduced on-site activities
• Environmentally stable product
• Rapid on-site build times achieved
• Virtual elimination of formwork
• Watertight construction
• Minimal site waste
• No wet trades required
• Reduced scaffold requirement
• Enhanced strength characteristics
• No down-time due to inclement weather
• Consistent quality
• Reduced noise during construction
Contact details
Contact: Paul Rogatzki
Address: Hanson Building Products
Birchwood Way
Cotes Park Industrial Estate
Somercotes
Derbyshire
DE55 4NH
Telephone: 01773 600252, mobile 07860 236530
Facsimile: 01773 603134
Email: [email protected]
Website: www.hanson.com/uk
innovation and achievement 2009improvements in site efficiency
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innovation and achievement 2009 50construction products association
Reynaers Ltd OptimaReynaers Optima window gear has been designed in conjunction
with a bespoke set of profiles, with manufacturing efficiency in
mind. Optima reduces stock, speeds production, increases quality,
reduces cost and increases profitability. Optima gear and Optima
profiles have been designed exclusively for Reynaers and reduces
the number of window gear components needed to make all
variation of tilt-n-turn, from around 90 parts down to only 20.
Along with the gear and the profiles, Reynaers created a five stage
automation system that enables mass production, including robotics
for gear mounting and factory glazing. The fully automated system
includes machine profiling, corner connection, automatic mounting
gaskets, automatic mounting gear as well as automatic gluing of
glass to the frame.
To accommodate variations in volume, Reynaers Optima gear can
be used either manually or as part of the fully automated process.
What is innovative or new?
• Enormous reduction in components needed compared to traditional tilt-n-turn windows
• Substantial increase in automation for the production of finished elements
• For the building end user, Optima offers the unique facility to retrospectively alter the opening operation of the window
How are benefits delivered?
• Due to faster manufacturing and a reduction in components, Optima speeds ordering and delivery to site
• The cost savings and quality improvements gained in the manufacturing process will benefit the whole supply chain
• For the low volume manufacturer, the manual fitting of these components has been simplified and speeded up with larger and heavier windows also possible
• Designing bespoke profiles, gearing and machinery together makes Optima the first aluminium system of its kind
Contact details
Contact: Rebecca Cope
Address: Reynaers Ltd
Kettles Wood Drive
Birmingham
B32 3DB
Telephone: 0121 421 1999
Facsimile: 0121 421 9797
Email: [email protected]
Website: www.reynaers.co.uk
innovation and achievement 2009improvements in site efficiency
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innovation and achievement 200951 construction products association
innovation and achievement 2009improvements in site efficiency
Aggregate Industries UK Lewisham Flag Paving DevelopmentThe Lewisham Flag was designed in conjunction with the Borough
of Lewisham. Previously they had used small element paving where
there was vehicle overrun. However they now wished to go to
a 600 x 600m size, which could possibly crack. The new product
therefore had to be reinforced using glass fibre and chamfered to
avoid possible slip/trip claims. However the real innovation was the
unique design of nibs and spacers in the mould tool to prevent sub
base erosion. This meant that the slabs could be laid on a sand
bed, as there was a shortage of skilled operatives able to bed in
mortar. The product adhered to the guiding principles of the new
“Streets For All” document from English Heritage.
What is innovative or new?
The design of the product means that a 600 x 600 x 63mm flag
pavour can now be used in areas where vehicular overrun is
a problem. The most important innovation is that the slab can
now be laid mortar-less on a sand bed, where previously mortar
was a necessity.
How are benefits delivered?
The benefits delivered are substantial, in that an aesthetic
solution can be found that ties in with the “Streets For All”
document. Very importantly a large format product is
sustainable in use with minimum risk of slips, trips and falls
complaints. Finally the product can be laid on a sand bed,
without the sub base and jointing sand being washed away by
street cleaning. Lewisham are delighted with the product.
Contact details
Contact: Mark Bushell
Address: Aggregate Industries
Hulland Ward
Nr Ashbourne
Derbyshire
DE6 3ET
Telephone: 01335 372222
Facsimile: 01335 370973
Email: [email protected]
Website: www.aggregate.com
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innovation and achievement 2009 52construction products association
innovation and achievement 2009improvements in site efficiency
DrillVent UK LimitedDrillVentWinner of Grand Designs - Best Innovative Building Product 2009,
DrillVent is a patented cavity venting system, designed for ease of
installation and certainty of use. Correct cavity ventilation and
drainage is achieved by simply drilling a hole and inserting the vent.
Once installed, a correctly vented and drained cavity is assured.
DrillVent’s patented design allows for efficient ventilation. The slatted
louvres are specifically designed to encourage ventilation whilst
inhibiting the ingress of large insects, rodents and precipitation.
Correct ventilation and drainage is vital to a cavity wall assembly to
ensure a healthy, long-life service of the building enclosure and
assembly components. Perpvents are regularly omitted, get blocked,
covered, damaged during the construction process or not installed
correctly. DrillVent offers an inexpensive, effective solution to
these traditional, reoccurring issues. With DrillVent, a healthier wall
will ensue. A dryer wall assembly reduces heating costs - an added
bonus to any property owner. An attractive, discrete finish is
achieved with ease.
What is innovative or new?
DrillVent is the only circular cavity vent of its type that has been
designed as a ventilator, gives confidence in use and is quick to
install. DrillVent can be easily retrospectively installed and has
been designed and tested to BS EN 13141-1 in association with
the Building Research Establishment.
How are benefits delivered?
Inadequate venting/drainage of a cavity wall can, over time, lead to
many problems such as dampness and rot. The premature
demise of the building structure, fabric and assembly component
may ensue, resulting in costly, time consuming and interruptive
remedial works.
By installing DrillVent, you are confident that the venting task
has been carried out correctly in accordance with local regulations,
warranties and best practice. The moisture content of timber
components are maintained at healthy levels.
Contact details
Contact: Kieran Gannon
Address: 1A Twitchell Road
Great Missenden
Buckinghamshire
HP16 0BQ
Telephone: 01494 890 518
Facsimile: 01494 890 518
Email: Kieran@ drillvent.com
Website: www.drillvent.com
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innovation and achievement 200953 construction products association
innovation and achievement 2009improvements in site efficiency
EcoTherm Insulation UK ltd UFH boardEcoTherm’s new Underfloor Heating Boards are manufactured
from rigid polyisocyanurate (PIR) foam with a protective “skin” on
both faces. The skin is made up of a heavy duty fibre mesh
laminated to an aluminium foil facing.
The boards are 1,200mm x 2,400mm and are available in
thicknesses of 25, 50 and 70mm depending on the insulation value
required. Thermal conductivity is exceptionally low, at 0.023 W/
mK, which means maximum insulation for minimum thickness.
The board is durable, will not shrink and offers good compressive
strength – 140kPa. Green credentials are also impressive – PIR
boards are zero ozone depleting, with a Global Warming Potential
(GWP) of only 3; considerably less than target value.
The boards can be used in solid concrete floors with screed
overlay, as well as suspended beam or block constructions with
battens and floating floor covering.
What is innovative or new?
Thanks to the reinforced aluminium woven facing UFH has superb
clip retention and eradicates the need for a protective membrane
whilst the printed grid makes for easy pipe and clip alignment.
How are benefits delivered?
SAVES TIME
• Printed grid makes it easier to align pipes accurately and efficiently
• Superior clip retention means fewer clips are required
• Light, easy to handle boards; cuts installation time by up to a half
SAVES MONEY
• Aluminium facing means no need for additional polythene sheet
• Saving on clips, pipe waste and time means you save money on materials and labour
Contact details
Contact: Dale Kaszycki
Address: EcoTherm Insulation UK Ltd
Harvey Road
Burnt Mills Industrial Estate
Basildon
Essex
SS13 1QJ
Telephone: 01702520166
Facsimile: 01702420636
Email: [email protected]
Website: www.ecotherm.co.uk
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innovation and achievement 2009 54construction products association
innovation and achievement 2009improvements in site efficiency
Hanson Building Products SPS Factory Management SystemSPS Factory Management System compares manufacturing line
performance and records relevant information during each
production run.
The production runs vary from excellent to poor due to varying
conditions. The product aligns recorded parameters to the good
and poor production runs to establish which conditions need to be
present and which need to be avoided.
The collected data is analysed and fed back to operational staff during
the production run, allowing changes to be made immediately to ensure
line performance corresponds to the best recorded production run.
A key feature is the ability to track cause and effect to several levels;
e.g., the effect might be damaged finished product; the cause may
be a misaligned piece of plant or equipment ,which in turn has been
altered due to poor quality raw materials. By establishing
the root cause of the problem and identifying it, changes can be
made to operational conditions during the production run.
What is innovative or new?
The product combines operational experience with objective
real-time plant monitoring; combining the subjective input from
operators with the objective data recorded.
The output from the system is used in two ways; - to allow
the operational staff to make changes during the production run,
to identifiy and evaluate repeated downtime reasons, allowing
accurate justification for future capital investment to eradicate
production problems.
How are benefits delivered?
The product delivers benefits by making operational staff aware of
the costs associated with plant stoppages. This leads to a combined
effort from maintenance and operational staff to continuously
put in place new procedures or plant replacement programmes
and to gradually increase plant performance, leading to a drop in
manufacturing costs per unit.
Apart from producing continuous costs associated with plant
stoppages, it delivers the cost of manufacture for each individual
product run.
As the manufactured cost per unit excludes raw material costs,
the product highlights only operational cost variations and is able
to associate deliberate changes to operational procedures with
plant performance.
Contact details
Contact: Steve Hudd
Address: SPS Ltd
Spring board innovation centre
Cwmbran
NP443AW
Telephone: 07989-566694
Email: [email protected]
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innovation and achievement 200955 construction products association
innovation and achievement 2009improvements in site efficiency
Kingspan Insulation Limited Kingspan ‘Roof in a Box’The ‘roof in a box’ is a new development of the popular Kingspan
Thermataper tapered roofing boards, introducing pre-mitred
boards thus providing a complete system ready for installation.
Pre-mitred to individual specifications, boards arrive ready labelled,
with a full set of installation instructions, so are easy to use.
Tapered insulation hips and valleys were traditionally cut on site
from square tapered insulation boards. Boards are now pre-cut in
the factory into a half hip section and a half valley section and only
the hip and valley components required are delivered to site.
The whole board is used, reducing the amount of waste material
from cutting boards on site from up to 50% to nil.
A free roof survey is available for refurbishment projects and all roof
plans are supplied on waterproof, tear-proof paper.
What is innovative or new?
Boards are factory pre-cut into a half hip section and a half
valley section, reducing the amount of waste material from
cutting boards on site from up to 50% to nil.
The introduction of tear-proof, waterproof plans followed
feedback from contractors about the difficulties of working in
all weathers.
How are benefits delivered?
This is a major step forward in improving site productivity and
reducing site waste from the installation of tapered roofing
systems. By eliminating the need for cutting boards on site,
installation time and labour cost is significantly reduced as is
the amount of waste material produced on site.
The entire system is designed to make life on site easier and
more productive as well as reducing waste to landfill. Even small
practical touches such as the waterproof plans help to achieve this.
Contact details
Contact: Peter Morgan
Address: Kingspan Insulation Limited
Pembridge
Leominster
Herefordshire
HR6 9LA
Telephone: 0870 850 8555
Facsimile: 0870 850 8666
Email: [email protected]
Website: www.insulation.kingspan.com
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innovation and achievement 2009 56construction products association
innovation and achievement 2009improvements in site efficiency
Saint-Gobain Isover ULTIMATE™ Protect The ULTIMATE™ Protect product range for fire insulation of
HVAC ductwork systems from Saint-Gobain Isover, is an innovative
mineral wool produced with the glass wool technology of Isover,
that combines all the advantages of conventional fire, thermal and
acoustic insulation.
Available in slabs and wired mat options, the ULTIMATE™ Protect
complete product range offers top level fire resistance, easy handling
and is 65% lighter than traditional stone wool, with the added benefit
of providing up to 50% better sound absorption than that of
competitive products.
ULTIMATE™ Protect is easy to cut with a standard lagger’s knife,
offers flexible shaping and allows off-cuts to be used, providing
a virtually waste-free installation. With no need for expensive
prefabrication and no need to glue joint lengths or duct surfaces,
ULTIMATE™ Protect can be installed in up to half the time of
traditional solutions, offering on-site efficiencies in both time and
cost savings.
What is innovative or new?
• Up to 65% lighter than traditional stone wool
• Up to 50% better sound absorption than competitive products
• Up to 50% faster installation time
• First mineral wool product to satisfy EN1366-1
How are benefits delivered?
• Effective fire protection – EuroClass A1 fire rating in accordance with EN1366-1
• Ease of installation
• Simple to cut
• Fast installation – up to 50% faster installation
• Lightweight – up to 65% lighter than traditional stone wool. Surpasses Health and Safety minimum requirements
• Optimal acoustic performance – up to 50% better sound absorption than competitor products
• Excellent thermal insulation performance
• Cost-effective solutions
• Maximum compressibility
• Outstanding flexibility
Contact details
Contact: Annemarie Shotton
Address: UK Commercial Centre
Gotham Business Park
Gotham
Nottinghamshire
NG11 0LB
Telephone: 0115 969 8016
Facsimile: 0115 983 1675
Email: [email protected]
Website: www.isover.co.uk
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innovation and achievement 200957 construction products association
innovation and achievement 2009improvements in site efficiency
SAS InternationalSAS Modular SolutionsSAS Modular Solutions designs and manufactures pre-fabricated,
walled mechanical and electrical modules. These modules can
include ductwork, ventilation ductwork, domestic LTHW CHW
pipework, electrical cables and cable trays and Medi-gas provision.
SAS offers the only modules on the market with an integrated wall
system. This enables individual fire rated and acoustic rated
modules to be specified and offers significant time savings for
interior fit-out.
Formed using an open metal Uni-strut frame system, each Service
Module contains the appropriate service and duct options pre-
installed, pre-configured, insulated and sealed.
Whilst pre-fabricated modules have been used in the construction
industry for decades, Mechanical and Electrical Service Modules
have become popular where large or complex infrastructure is
demanded to meet today’s building standards.
Demands for outstanding value and strict build times require
on-site efficiencies. SAS Modular Solutions offer a genuine and
innovative contribution to this, providing significant programme and
logistical savings.
What is innovative or new?
SAS Modular Solutions uniquely offers an integrated wall
system, assuring accuracy and speed of installation in fit-out.
Factory fitting M&E services/apertures within the modules
ensures quality control.
Sealing pipework/fittings from day one prevents contamination.
Factory build, conducted at ground level, means less time spent
working at height on site.
How are benefits delivered?
Faster construction programme – it takes less than a week to
manufacture 35-45 six-metre M&E modules.
Individual fire and acoustic rated modules can be supplied.
Modules quickly and easily positioned and connected on site.
Additional Health and Safety benefits with multi-trade interfaces in
restricted work areas avoided. Less time is spent working at height.
Continuing maintenance access requirements of the building
taken into account at early stages.
Reduction in material waste and less site accommodation required.
Contact details
Contact: Andrew Jackson
Address: SAS International
31 Suttons Business Park
London Road
Reading
RG6 1AZ
Telephone: 0118 929 0900
Facsimile: 0118 929 0912
Email: [email protected]
Website: www.sasint.co.uk
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innovation and achievement 2009 58construction products association
innovation and achievement 2009improvements in site efficiency
SmartPly Europe Ltd SmartPly SiteProtectSmartPly SiteProtect has been manufactured on our new high
technology coating line and produced in partnership with our
coating supplier. The SmartPly OSB3 substrate has been coated
with a smooth, heavy duty exterior, cross linked polymer surface
treatment. This pre-coated product eliminates the need for
priming thus reducing installation costs and enabling a high quality
paint finish. The product is certified by the Forest Stewardship
Council (FSC).
SiteProtect is ideal for use in a wide range of applications from
temporary hoarding through to a variety of security installations.
What is innovative or new?
SiteProtect was developed as a site hoarding for all types of
construction and temporary works which is vital for safety and
security and must be simple to erect, strong and durable;
our research also revealed the importance of presenting a top
quality image which is why we have made it smooth and easy to
paint well.
How are benefits delivered?
The product is pre-coated, no need to prime, has a smooth
durable finish so that logos can be applied directly and fewer
coats of paint are needed for corporate colour applications,
thus reducing on-site costs.
Also in keeping with current construction methods of working
towards healthier environments this product has been
manufactured using zero-added formaldehyde and the coating
is inert and therefore does not emit any harmful compounds.
Contact details
Contact: Paul Doherty
Address: SmartPly Europe
Belview
Slieverue
Waterford
Ireland
Telephone: 00353 51 851233
Facsimile: 00353 51 851130
Email: [email protected]
Website: www.smartply.com
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innovation and achievement 200959 construction products association
innovation and achievement 2009improvements in site efficiency
FP McCann LtdEasi-BaseEasi-Base replaces the site practice of constructing bases for
manholes. Currently the practice involves creating bases and rough
benching from ready-mix concrete; using clay, concrete or uPVC
channels to connect the inlet, outlet and branches together.
Operations are usually carried out in a deep water logged pit with
trench supports in place for long periods of time used to protect
the operatives during construction. Integrity failures both in concrete
forming the base and in the connection between the channel and
concrete can be a common occurrence. The failures generally
exhibit in the form of leakage of contaminated water escaping from
the manhole (causing pollution) and / or groundwater percolating
into the manhole (increasing costs of sewage treatment).
Easi-Base utilises a polypropylene liner which allows for prefabrication
of channels and sealed connectors, encased in concrete providing
structural integrity and strength. As the unit is precast it is ready
for immediate use.
What is innovative or new?
Easi-Base utilises a polypropylene liner which allows for prefabrication
of channels and connectors. This is then encased in concrete
which provides the structural integrity and strength. It is the
combination of the concrete and polypropylene that make up
the technology in Easi-Base.
How are benefits delivered?
Easi-Base is a unique drainage product benefiting the end user,
the contractor and the tax payer. Major savings are made when
considering the treatment of contaminated groundwater, and
the costs incurred at the sewage treatment works in having to
treat increased volumes of groundwater. Easi-Base also increases
speed of construction whilst guaranteeing quality. It has major
health and safety benefits as less time is spent in the manhole.
Easi-Base has an 80 year guarantee.
Contact details
Contact: Aidan Scullion
Address: 3 Drumard Road
Knockloughrim
Magherafelt
N. Ireland
BT45 8QA
Telephone: 028 7954 9044
Mobile 07809553040
Facsimile: 028 7954 9993
Email: [email protected]
Website: www.fpmccann.co.uk
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innovation and achievement 2009resource efficiency
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The construction industry is one of the largest users of raw materials, which when managed effectively play a crucial role in ensuring the sustainability of our built environment.
Many of the policies surrounding better resource management are driven by the European Union, which in recent years has published the Thematic Strategies for Waste Prevention and Recycling and Resource Management. The Waste Framework Directive was concluded late in 2008 and it is expected that the requirement
to reduce construction waste by 70% over the next decade will drive innovation.
The Association is closely involved in delivering greater opportunities to develop products that address total life-cycle impact.
The examples highlighted this year, again demonstrate how manufacturers have either replaced virgin materials with secondary materials or ensured that manufacturing and product use reduces the environmental impact on the built environment.
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innovation and achievement 200962 construction products association
innovation and achievement 2009resource efficiency
ICI Paints AkzoNobel Dulux Trade Paint SolidifierAs part of its exemplary ‘Step Towards Greener’ Programme,
Dulux Trade has launched the Dulux Trade Paint Solidifier, a unique
and revolutionary waste management product. Designed to enable
the disposal of unwanted water-based paint safely and responsibly,
just one 25g dose of the product is enough to solidify 500ml of
leftover water-based paint. Once the product has been added to
the paint, a process of coagulation occurs which turns the paint
from a liquid into a solid state, resembling a crumble-like
consistency. In this form the paint is inert and will never turn back
into paint even when immersed in water.
Once treated, the solid waste paint can be disposed of via a
non-hazardous waste stream alongside other normal construction
waste, leaving you with a can, clean enough to recycle. Not only
does this promote the safe and legal disposal of water-based paints,
but also reduces the amount of paint containers going to landfill.
What is innovative or new?
Dulux Trade Paint Solidifier eliminates the practice of sending
leftover liquid paint to landfill or pouring it down a drain.
When the product is mixed with the leftover paint, it is
solidified in the can and then the resulting end product can be
treated as normal household waste.
How are benefits delivered?
• Solves problem of disposing of liquid paint responsibly as non-hazardous waste. Eliminates other disposal measures that involve heavy costs via a special waste management company or the paint being irresponsibly poured down the drain or mixing with sawdust on site
• No water required - convenient on site
• Coagulates in 3-4 minutes - quick and easy disposal
• Cleans sides of the can - allows can to be recycled
• Allows differentiation for the decorator/contractor and enables them to win clients with environmental credentials instead of price
Contact details
Contact: Corinna Palin
Address: ICI Paints AkzoNobel
Dulux Trade
Wexham Road
Slough
Berkshire
SL2 5DS
Telephone: 01753 877891
Facsimile: 01753 877413
Email: [email protected]
Website: www.duluxtrade.co.uk
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innovation and achievement 2009 63construction products association
innovation and achievement 2009resource efficiency
Aggregate Industries UK Dry Grinding and PolishingInstead of conventional wet grinding, dry grinding uses no water,
saving 300 cubic metres per annum. It reduces electricity by 28%
and there is also no waste slurry saving 850 tonnes per annum.
By not having to stop the machine to dispose of this waste, it
increases efficiency enabling a further 850 tonnes of product to be
produced per annum. Also very importantly, the dust generated
from the dry grinding process can be placed back into the original
product mix, which means that a further 850 tonnes of aggregate
are saved.
The dry grinding process halves the reject rate of the product from
12% to 5%.
The lack of water also improves working conditions including health
and safety.
Raw material is reduced and no slurry produced.
The longevity of the equipment is increased substantially with dry
grinding and polishing giving a saving of 25% on maintenance and repairs.
What is innovative or new?
This is the first time that dry grinding and polishing has been used
on paving products in the UK and possibly the world. Previously
this technology had not been successfully implemented.
The knowledge gained during this process may see dry grinding
replace wet grinding, with all the associated benefits.
How are benefits delivered?
The major benefit is in resource efficiency, saving water, raw
aggregate material, waste with its associated issues and time.
The savings generated by this process are substantial and the
company has become expert in the process for further
implementation across the group.
Contact details
Contact: Paul Lane
Address: Aggregate Industries
Hulland Ward
Derbyshire
DE6 3ET
Telephone: 01335 372222
Facsimile: 01335 370973
Email: [email protected]
Website: www.aggregate-uk.com
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innovation and achievement 200964 construction products association
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Filon Products LimitedGRP (Glass Reinforced Polyester) Recycling GRP is a notoriously difficult material to break down. It has been
widely regarded that the only viable option for disposing of waste
GRP was landfill. Filon’s unique new GRP Recycling Plant enables
a two-stage process by which the GRP can be cost-effectively
reduced, first to small flakes of approximately 10mm sq. and then
to a fine powder. The material in both of these states can be
recycled for use in manufacturing processes.
Tests have indicated that a percentage of recycled material has no
detrimental effect on the performance of GRP products, in terms
of strength, light transmission, light diffusion or durability.
Filon’s product range, incorporating recycled material will include
rooflights, valley troughs, flat roof flashings and opaque sheeting.
Filon is now able to fully recycle their own GRP waste products.
What is innovative or new?
We believe this is a UK first and the recycling plant has been
built specifically for Filon’s needs. It is the first time in the UK
that GRP has been ground to a powder for reuse in its
manufacturing process.
How are benefits delivered?
It reduces pressure on landfill sites, eliminates manufacturing
waste, is cost effective and a genuine contribution to sustainability.
Contact details
Contact: David Hathaway
Address: Unit 3
Ring Road
Zone 2
Burntwood Business Park
Burntwood
Staffordshire
WS7 3JQ
Telephone: 01543 687 370
Facsimile: 01543 687 303
Email: [email protected]
Website: www.filon.co.uk
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innovation and achievement 2009 65construction products association
innovation and achievement 2009resource efficiency
Johnson Tiles - (a trading division of Norcros Group (Holdings) Limited) Ink-jet Decoration of Ceramic TilesJohnson Tiles installed a new ceramic ink-jet printer in July 2008.
This represents the cutting edge of ceramic decoration methods
and has a number of advantages over existing decoration methods:
• Non-contact, digital printing offers unlimited image variations and eliminates the need to print minimum quantities
• Superior image quality, definition and dynamic range over other printing methods. The inks provide a large colour gamut and high densities with just four colours to produce all colours and shades. Realistic imitations of natural products such as stones and marbles can be produced
• It prints onto the same glazes used with conventional printing systems
• Endless variations can be created giving random effects
• New designs can be created much faster and at lower costs - unique custom designs are now possible
• Tiles can be printed with highly profiled surfaces and 100% edge to edge, unlike other printing methods
What is innovative or new?
Johnson Tiles is the first UK ceramics manufacturer to install,
operate and market products decorated using the world‘s first
industrial-scale inkjet printer using specially formulated,
pigmented ceramic inks to digitally decorate ceramic floor and
wall tiles, offering significant economic benefits as well as
superior design advantages over traditional systems.
How are benefits delivered?
The process replaces rotary contact printing methods with a
non-contact system. It has reduced breakages of unfired tiles
on the production line by around 1.5%. Ink-jet printing uses
only four inks (cyan, magenta yellow and black), producing a
wide pallet of continuously variable shades. It is self-cleaning
and produces no waste. Other printing techniques are
restrictive on design and use single colour inks, requiring a
range of 240 separate inks for our existing product range.
Contact details
Contact: Tony Cotton – Head of Manufacturing
Address: Harewood Street
Tunstall
Stoke-on-Trent
Staffordshire
ST6 5JZ
Telephone: 01782 575575
Facsimile: 01782 577377
Email: [email protected]
Website: www.johnson-tiles.com
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innovation and achievement 200966 construction products association
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ACO Technologies plcVIENITE®
ACO has traditionally manufactured a range of drainage channels
from Polymer Concrete, a material that has approximately four
times the compressive strength of conventional concrete.
Polymer concrete also has the advantage of making products much
lighter than POC concrete – half the weight of an equivalent
section; it was also a material that could only incorporate virgin
materials.
During 2007/08, ACO developed a new material known as
VIENITE®. (patent pending). The most important feature of the
new material is that it was developed specifically to utilise high
levels of post-consumer recycled waste into its makeup, without
compromising any strength characteristics, consistency in material
properties or product life and performance.
All ACO channels that were previously manufactured in polymer
concrete are now manufactured in VIENITE®, thereby dramatically
reducing the amount of virgin material used.
In addition to VIENITE® using recycled material as a constituent
element, VIENITE® itself can now be 100% recycled.
What is innovative or new?
Incorporating recycled waste into a material is difficult to do
without compromising its properties. This can adversely affect
the manufacturing process and final product quality.
VIENITE® (patent pending) is used in Kitemarked products,
meaning not only does it meet all required performance criteria,
but does so every time.
How are benefits delivered?
Using recycled materials is an important element objective of the
UK Framework for Sustainable Development. Regional and local
authorities require recycled content in regional spatial strategies,
planning policies and supplementary planning documents.
Traditionally, there has been a legitimate concern about the use of
recycled material causing sub-standard performance in product.
However, VIENITE® has been developed creating a material that
meets the highest European standards, thereby giving the best
possible level of quality assurance to ACO’s products.
Contact details
Contact: Peter Ridgway
Address: ACO Technologies plc
Hitchin Road
Shefford
Beds
SG17 5TE
Telephone: 01462 816666
Facsimile: 01462 850846
Email: [email protected]
Website: www.aco.co.uk
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innovation and achievement 2009 67construction products association
innovation and achievement 2009resource efficiency
Profile 22 Systems Northwards Pilot – 100% Recycled Windows installationProfile 22 is the first systems company to manufacture a prototype
PVC-U window from 100% recycled material.
The Northwards Pilot scheme, run by Northwood Housing
supported the delivery of a pioneering commercial installation of
PVC-U windows manufactured from recycled material.
Northwood Houusing is responsible for managing and maintaining
almost 13,000 properties and is the first social housing provider in
the UK to specify and complete a PVC-U window replacement
project, installing windows manufactured solely from recycled
material.
To ensure colour consistency, weather performance and to deliver
improved aesthetics, the window profile supplied by Profile 22 also
featured a thin white wood grain effect virgin material foiled skin
(two per cent of total).
PVC-U is totally recyclable and is now used in all windows and
component window parts as standard.
What is innovative or new?
Although it remains a pilot project, this is representative of a
new opportunity to the social housing sector. As thousands of
tonnes of old PVC-U are brought back into use - material that
might otherwise have gone to landfill.
This innovative ‘green’ new build window system, combines an
overall recycled content of up to 60% with the very latest in
advanced performance energy WER rated ‘A’ to ‘C’, energy
efficient window technology.
How are benefits delivered?
• Reduces carbon footprint
• Closed looped recycling
• PVC-U can be recycled more than ten times without deterioration in service performance and has a total life span of 400 years.
• Sustainable whole life costings
• Commitment to the Vinyl 2010 initiative
• Exceeds BRE’s target for recycled content without impacting on product quality
Contact details
Contact: Andrew Reid
Address: Profile 22 Systems
Stafford Park 6
Telford
Shropshire
TF3 3AT
Telephone: 01952 290910
Facsimile: 01952 290460
Email: [email protected]
Website: www.profile22.co.uk
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innovation and achievement 200968 construction products association
innovation and achievement 2009resource efficiency
CEMEX UK Readyflow®; a new concrete block permeable paverBuilding materials supplier CEMEX UK has launched Readyflow®,
a new concrete block permeable paver. The new paver has
a unique interlocking shape and can be used as an integral part of
a Sustainable Urban Drainage System (SUDS), a solution to combat
excessive surface water caused by rain and flooding.
Readyflow® is an attractive paving solution. It allows surface water
to pass through the voids in the block design into a sub grade or
drainage system, where it can be effectively managed. It is estimated
that around two thirds of the 55,000 homes affected by the 2007
summer floods were flooded from surface water run-off.
Rainfall which would normally be absorbed and retained by
the ground is often diverted off the sealed area, into the sewers
and rivers. This results in the overload of sewers, river flooding and
the risk of pollution into the water course. Readyflow® creates a
permeable surface allowing water to pass through in a controlled
manner. The water can then either be retained and re-used or
alternatively discharged in a controlled manner leading to reduced
rainfall into sewers, cleaner rivers and streams, less pollution,
improved ground water levels and water and air to the plant and
tree roots.
What is innovative or new?
• Readyflow® has a unique interlocking shape, and when used as part of a SUDS system, it allows a specified amount of water to be retained and then discharged in a controlled manner
• The environmental credentials of this new block extend beyond their usage as it is made from CEMEX CEM II cement. The factory blended CEM II cement is supplied locally and comprises of Portland cement (CEMI) and PFA (which is a by-product of the power industry)
How are benefits delivered?
• Readyflow® used as part of a SUDS system allows a specified amount of water to be retained, and then discharged in a controlled manner. Approximately 2.4 litres of water per sq metre can be discharged per second
• The controlled discharge of water leads to less rainfall into sewers, cleaner rivers and streams, less pollution, improved ground water levels and water and air to the plant and tree roots
• The use of PFA as a raw material reduces the carbon footprint of the product significantly by up to 40%
Contact details
Contact: Garry Gregory
Development Manager
CEMEX Concrete Products
Address: CEMEX House
Evereux Way
Rugby
Warwickshire
CV21 2DT
Telephone: 01788 517000
Email: [email protected]
Website: www.cemex.co.uk
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innovation and achievement 2009 69construction products association
innovation and achievement 2009resource efficiency
Hanson UK Recycled road planings dryerA £1.67 million dryer at Hanson’s West Drayton asphalt plant in
Hillingdon, Middlesex, allows the plant to use recycled materials in
base course asphalts at rates of up to 50%, improving efficiency,
reducing costs and cutting its carbon footprint.
The Benninghoven dryer is the first to be installed in a UK asphalt
plant. It allows a greater proportion of recycled road planings to be
added to the mix because the material is dry and hot, saving both
bitumen and quarried stone.
The dryer, which can handle up to 160 tonnes an hour, includes six hot
storage hoppers with automatic weight systems to minimise waste,
a mobile impact crusher and new stock bays. It runs on reclaimed
fuel oil and uses technology that doesn’t burn the bitumen or make
harmful emissions.
The additional hoppers mean wastage and fuel usage are reduced
and customer service is improved.
What is innovative or new?
This is the first plant of its type to be installed in a UK asphalt plant.
It has enabled West Drayton to be the first Hanson UK plant to
reach the company’s 2010 target of 25% recycled materials in
base course asphalt.
How are benefits delivered?
It allows a much greater proportion of recycled road planings to
be added to the mix. Cold planings can only be added at rates
of up to 10% without compromising the mixing process and
product quality. It also reduces waste and energy use.
Contact details
Contact: David Weeks
Address: Hanson UK
The Ridge
Chipping Sodbury
Bristol
BS37 6AY
Telephone: 01454 316000
Facsimile: 01454 325161
Email: [email protected]
Website: www.hanson.com/uk
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innovation and achievement 200970 construction products association
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Hanson UKRecycling inorganic waste for use in cement Solvent Resource Manager (SRM) is a subsidiary of Hanson UK’s
cement division. It is one of the biggest solvent recyclers in Europe
and provides waste-based alternative fuels for the cement making kilns.
Minerals Resource Management (MRM) was created by SRM in
2008 to provide a disposal service for recycling inorganic waste
materials for use in cement making. The company is reclaiming
gypsum from plasterboard and trialling scallop shells as a replacement
for natural limestone in cement.
What is innovative or new?
It is the first business of its kind in the UK to target alternative
raw materials for use in cement manufacture.
How are benefits delivered?
It enables Hanson to replace some of the natural limestone used
in cement, conserving valuable mineral resources. It also reduces
the amount of inorganic waste going to landfill.
Contact details
Contact: David Weeks
Address: Hanson UK
The Ridge
Chipping Sodbury
Bristol
BS37 6AY
Telephone: 01454 316000
Facsimile: 01454 325161
Email: [email protected]
Website: www,hanson.com/uk
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innovation and achievement 2009 71construction products association
innovation and achievement 2009resource efficiency
Lafarge ReadymixUse of by-products within concreteOne of our principle objectives is to reduce the amount of raw
material used in concrete. Reduction is important but especially
so if a by-product from another area of the business can be used, as
is the case at Lafarge.
By incorporating crushed rock fines into some of the concrete
produced by Lafarge, the amount of waste produced by aggregate
production is reduced and the blending of this waste product
reduces the need and use of primary material. These by-products
are treated with a clay neutraliser specially designed by Lafarge.
It has been discovered that higher strength gain has been achieved
when using by-products in some areas as opposed to conventional
materials and the replacement itself offers numerous environmental
and sustainable benefits.
What is innovative or new?
The use of by-products within concrete is a new process. There has
always been waste but we are now in a position to find the correct
uses for it.
How are benefits delivered?
This process reduces CO2 and waste going into landfill as well as
the added benefit of reducing the use of primary sands within
concrete. The resulting strength gain offered gives an improved
customer, BREEAM and green guide status.
Contact details
Contact: Emma Hines
Address: Granite House
Watermead Business Park
Syston
Leicestershire
LE7 1PF
Telephone: 07803 953935
Email: [email protected]
Website: www.lafarge-aggregates.co.uk
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innovation and achievement 200972 construction products association
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Milliken ContractOmni® Access All Areas with Tractionback™
Omni Access All Areas is a sustainable range of modular carpet,
which can be quickly installed, without the need follow directional
arrows and without the need for large areas of adhesive.
The innovative product construction incorporates an 85% recycled
content polyurethane cushion and is typically 25% lighter than
hardback modular carpet. It has one of the lowest face weights for
reduced resource usage, yet still maintains the highest levels of
performance available. • Class 33 Heavy Commercial Use rated
• Ten year wear guarantee
• 34dB impact sound rating (best in industry)
• Underfoot comfort / ergonomics
• Extended appearance retention
The Omni design is visually seamless on the floor and requires no
‘bedding in’
Laid randomly, for quick and easy installation with waste reduced
by up to 75%. Installation is further simplified by specifying the option
of TractionBack, a high friction coating which eliminates the need
for large areas of adhesive.
What is innovative or new?
This product combines the benefits of light weight product
construction, with Omni directional styling, and TractionBack
installation. These features combine to deliver the benefit of
a sustainable product that is quicker, easier and less wasteful to
install, and which offers total flexibility in use for today’s rapidly
changing work spaces.
How are benefits delivered?
• Light weight – 25% less resource – less transport – less end of life product disposal
• 85% recycled cushion backing for increased longevity, and improved performance, acoustics, and comfort
• 11% total recycled content, manufactured with green electricity, BRE A rated, carbon neutral certified.
• OMNI styling for 75% reduced installation waste, more rapid installation and flexibility of use
TractionBack friction coating for quicker simpler installation,
eliminates adhesive and adhesive packaging waste and
associated VOCs
Contact details
Contact: Customer services
Address: Milliken Contract
Beech Hill Plant
Gidlow Lane
Wigan
WN6 8RN
Telephone: 01942 612777
Facsimile: 01942 826570
Email: [email protected]
Website: www.millikencarpeteurope.com
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innovation and achievement 2009 73construction products association
innovation and achievement 2009resource efficiency
Profile 22 Systems 60% recycled content window system Profile 22 has developed an innovative ‘green’ new build window
system. It combines an overall recycled content of up to 60% with
the very latest in advanced performance energy WER rated ‘A’ to
‘C’, energy efficient window technology.
The window system features thermally efficient reinforcements
(including sashes, transoms, mullions and outerframe) manufactured
solely from 100% recycled composite material (RCM), the 98%
recycled content Winfast cavity closer and a cill with a 92%
recycled content, co-extruded with a virgin skin to deliver superb
weather performance and superb aesthetics.
These innovations in PVC-U building technology have made a significant
contribution in PVC-U’s recent ‘A’ and ‘A plus’ Green Guide rating
from the Building Research Establishment – something that also
scores PVC-U windows additional points under the Code for
Sustainable Homes.
What is innovative or new?
The Profile 22 new build system represent a significant stride
forward in PVC-U building technology, improving not only
environmental performance but also on-site efficiency –
something that is also going to be important as the new build
and social sectors play catch up on housing targets. It is easy to
fabricate and can be installed on site in minutes.
How are benefits delivered?
• Ensures Building Regulations compliance including Document L
• Designed for cavities 75 mm – 100 mm
• 60% recycled content window system
• Contributes to PVC-U ‘A’ and ‘A plus’ green guide rating
• Allows windows to be fitted internally
• Saves time on site
• Speeds up delivery of new homes without sacrificing sustainability
• Reduces use of virgin materials
Contact details
Contact: Andrew Reid
Address: Profile 22 Systems
Stafford Park 6
Telford
Shropshire
TF3 3AT
Telephone: 01952 290910
Facsimile: 01952 290460
Email: [email protected]
Website: www.profile22.co.uk
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innovation and achievement 200974 construction products association
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Swish Building Products Sustainable Rainwater System Swish Rainwater systems are for domestic and commercial
applications. They look and perform like conventional PVC
systems, however they contain a high proportion of post consumer
recycled PVC.
Approximately 84% by weight of the gutters and pipes in the Swish
system is composed of recycled material which is derived from post
consumer waste streams. This results in a 70% carbon saving.
This makes the systems ideal for social housing providers,
housebuilders and contractors who wish to specify products that
have a reduced carbon footprint.
The core recycled material in these gutters and pipes is grey and
has been left this colour in order to avoid the unnecessary use of
additional tinting agent. The outer skin is virgin material that is
co-extruded on to the surface of the core to enhance the finished
appearance.
Available in Round, Square, Ogee and Deepflow with square or
round down pipes. Colours are White, Black and Brown.
What is innovative or new?
This process is unique. Post Consumer Waste (PCW) is distinctly
different from post production waste. It is more difficult to
collect, sort and grade. Using PCW in construction products is
a positive step towards closing the PVC production loop thereby
reducing both landfill and virgin material production.
How are benefits delivered?
The production of new PVC components from recycled material
requires a fraction of the energy needed to make virgin PVC.
Swish has calculated that the production of its gutters and pipes
produces 70% less CO2 than would be the case if they were
manufactured from 100% virgin material. However Swish gutter
and pipe profiles exhibit the same strength, weather resistance
and longevity characteristics displayed by virgin material.
Contact details
Contact: Greg Wilde
Address: Pioneer House
Mariner
Lichfield Rd Ind Estate
Tamworth
Staffs
B79 7TF
Telephone: 01827 317200
Facsimile: 01827 317201
Email: [email protected]
Website: www.swishbp.co.uk
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