Farrat Thermal Breaks help reduce energy loss across New Bailey Scheme

Two New Bailey Square - Update from Site May 2019

Following our recent supply of Structural Thermal Breaks to Greater Manchester’s newest state-of-the-art office development One New Bailey, Farrat have also been appointed to thermally insulate structural connections at the second office building in the major mixed-use scheme, Two New Bailey Square.

The developments are expected to be complete by the end of 2019 and are being delivered by the English Cities Fund – a joint venture between Muse Developments, Legal & General and Homes England.

Both buildings have been specified to achieve Grade A BREEAM “Excellent” Standard, offering pre-let tenants such as Salford City Council and Eversheds Sutherland, best in class office environments built to the highest sustainability credentials. Integrating Farrat Structural Thermal Breaks between horizontal and vertical connections of both internal and external elements, will prevent thermal bridging in structural connections and significantly reduce heat loss across each building.

There a 5 projects currently underway in the New Bailey master scheme in total, each occupying a prominent position opposite Manchester’s internationally renowned Spinningfields business district.

New Bailey Scheme Masterplan - courtesy of Cushman & Wakefield

Farrat’s BBA certificated Structural Thermal Break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat Structural Thermal Breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

Farrat supply Structural Thermal Breaks to insulate connections across a 15,000t steelwork package, being erected at the new Edinburgh St James retail scheme

Edinburgh St James with egg shaped W Hotel

Edinburgh St James is one of the most significant construction and regeneration projects currently under way in the UK and the largest city centre development Edinburgh has seen for decades.

The £1bn project is replacing a 1960s shopping centre with 79,000m² of new retail space, alongside a new five-star W Hotel, an Aparthotel, 152 prime residential apartments, more than 30 restaurants and the city’s first Everyman Cinema.

Numerous column grid patterns requiring hundreds of tonnes of transfer structures, are helping to create the large retail-led mixed-use scheme, with a steelwork package totalling 15,000t of steel being fabricated by the appointed steelwork contractor BHC.

Following specification by the Architect, Farrat are set to supply over £90k of Farrat TBK Structural Thermal Breaks to thermally separate steel connections across buildings in the project.

Edinburgh St James main retail mall, which sits above a car park
Edinburgh St James - smaller residential grid sits above the retail elements of the project

As of March 2019, BHC had erected approximately one-third of the overall 15,000t of steel, a total that amounts to the company’s largest ever project. The steelwork package is due to complete in June 2020, with the project opening in phases, beginning with the retail and leisure element anticipated to complete in 2020, and the remainder of the development in late 2021 when the W Hotel and residential parts will be ready.


Farrat’s BBA certificated Structural Thermal Break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat Structural Thermal Breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

Farrat join the British Constructional Steelwork Association (BCSA) as Industry Member

Farrat are now a member of the BCSA

Farrat have been granted Industry Membership to the BCSA following independent assessment of our role as a UK manufacturer and supplier of Structural Thermal Breaks.  

The BCSA is the national organisation for the steel construction industry in the UK.

Industry Members are recognised as principal companies involved in the direct supply of components and materials used in structural steelwork and must have a purchase, design and supply facility within the UK.

Farrat are proud to be joining the BCSA in line with our continued commitment to the steelwork sector as an accredited & reliable manufacturer and a top-tier supplier of Structural Thermal Breaks.

Thermally insulating steelwork at the Centre for Environment, Fisheries and Aquaculture Science (Cefas)

CEFAS will incorporate an exposed steel frame that will insulated using farrat structural thermal breaks

Farrat are currently helping to deliver a cost-efficient and sustainable HQ building for the Centre for Environment, Fisheries and Aquaculture Science (Cefas) by thermally insulating the exposed steel frame using Farrat Structural Thermal Breaks.

Based in the Suffolk, the UK marine science agency Cefas (The Centre for Environment, Fisheries and Aquaculture Science) is constructing a new £18.3M contemporary headquarters building. The new headquarters will be a sustainable steel-framed landmark and form a central element of a much larger scheme that also includes the phased floor-by-floor refurbishment of an existing 1980s laboratory building.

The building has a composite design with steelwork supporting metal decking and a concrete topping. Most of the steel frame is based around a regular 6m column spacing, with internal spans of up to 12m.

This was deemed sufficient to provide the new building with modern open-plan office and meeting room spaces.

Farrat were recently contacted by the steelwork contractor to help minimise the risk of thermal bridges forming at several different penetrations and transitions in the building envelope.

CEFAS - Model of the steel frame

CEFAS – Model of the steel frame (courtesy of H Young Structures)

 

As the complete system needs to be optimised structurally as well as thermally, Farrat are supplying a combination of Farrat TBK and Farrat TBL thermal break plates in a variety of thicknesses and bespoke hole configurations, to ensure that the system is robust as well as thermally efficient.

The high compressive strength and low thermally conductivity properties of these Farrat Structural Thermal Break materials mean that they will transfer high loads and absorb any bending moments or shear forces, whilst acting as a thermal insulator.

The Cefas project is expected to be complete by May 2020.


Farrat’s BBA certificated structural thermal break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat thermal breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

Independent Review of Building Regulations and Fire Safety

Building Regulations and Fire - Farrat Independent Review

CONSTRUCTION INSIGHTS

INDEPENDENT REVIEW OF DEC 2018 AMENDMENT TO BUILDINGS REGULATIONS ‘SI 2018/1230’: USE OF NON COMBUSTIBLE MATERIALS

February 14, 2019
Author: Chris Lister, Commercial Manager

Synopsis of amendment

Following the recent amendment to the Building Regulations for Fire (England & Wales) SI 2018/1230 Farrat have been looking at the implications for Structural Thermal Break materials in the new legislation.

The statutory Instrument, issued in Dec 2018 sets out the effective prohibition of combustible materials in the external walls of high rise residential buildings over 18 meters. The amendment implements these changes via explicit regulation rather than guidance, making it an effective ban on any materials not reaching the prescribed certified standard.

The standard for prescribing performance in this case is BS EN 13501-1:2007+A1:2009 entitled “Fire classification of construction products and building elements. Classification using test data from reaction to fire tests” The prescribed level of performance required under this standard for use over 18 meters is European Classification A2-s1, d0 or A1.

BS EN 13501-1 defines the classes A1 and A2 as follows:

  • Class A1 will not contribute in any stage of the fire, including the fully developed fire.
  • Class A2 Will not significantly contribute to the fire load and the fire growth in a fully developed fire

The characteristics “s” and “d” are defined as follows:

  • s1 Weak or no smoke
  • s2 Medium Smoke
  • s3 High Smoke
  • d0 No dripping at all
  • d1 Slow dripping recorded
  • d2 High dripping recorded

The amendment only recognises classifications from European Norm standard. The older British Standard classification, which was recognised in previous guidance, is not included in the new regulation.

The New regulation applies to the building external envelope or specified attachments such as, balconies, bris solei or solar panels on ‘relevant’ dwellings, residential or institutional buildings above 18 meters or 6 storeys. Where the building is a hotel or hostel, boarding house or any other building type above 18 meters the regulations revert to the current Approved Document B requirements for fire of limited combustibility A2,-s3, d2 or better.

Within the new regulation for ‘relevant’ buildings above 18 meters, some building elements of the external envelope are exempt from the A1 & A2 fire performance rating.

This exemption includes door and window frames, glazing, fixings, gaskets and significantly for Farrat, thermal break materials.

Significance of the amendment to Building Regulations for Structural Thermal Breaks

Following their exemption from the recently amended standard for a fire classification, Structural Thermal Break materials, as currently supplied into the UK construction sector and deemed to be for the purpose of meeting the thermal bridging requirements of Approved Document L, can continue to be used under their existing limitations.

However, as with previous base line regulatory exemption, where building designers identify fire performance of construction materials as a higher significance factor, the testing and classification of all component’s planned for use will come under scrutiny.

To this end, alongside the continued development of new materials with Structural and Thermal properties, performance in respect of fire has become a main element in product manufacturers list of required characteristics.

As with all insulating materials there is generally a trade-off between insulation value and structural integrity. In the field of structural thermal breaks this balance is critical. Where structural performance is elevated to pole position, the goal is to achieve as good a thermal conductivity as possible without compromising structural properties.

With the introduction of fire into the equation the balance becomes three way, with Structural performance required to be maintained in the event of a fire whilst still functioning as a thermal break under everyday conditions.

The development of a new Structural Thermal Break material by Farrat has achieved this.

Farrat has utilised it’s full material R&D capabilities to develop the UK’s first Fire-Resistant Structural Thermal Break material: Farrat TBF.


If you’re interested in learning more about Farrat’s TBF Fire-Resistant Structural Thermal Break material ahead of the official launch,  please contact Chris Lister, Commercial Manager, on cl@farrat.com.

Chris Lister, Commercial Manager at Farrat

E: cl@farrat.com
T: +44 (0) 161 924 1602
LinkedIn: Chris Lister

AUTHOR PROFILE:

COMMERCIAL MANAGER,
CHRIS LISTER

Joining our UK office in October 2018, Chris is an Associate Member of RIBA and life member of Port Sunlight Rugby Club as Chairman.

Chris has over 30 years experience working within the UK Construction Product sector and leads our Thermal Breaks Team in the UK.

Areas Of Expertise: Product Design, Project Management, R&D
Time at Farrat: 6 Months

Farrat Thermal Breaks reduce energy loss in London’s new ‘City Cluster’

Londons new City Cluster

22 Bishopsgate is one of 13 major build projects expected to change London’s skyline by 2026.

Designed by PLP Architecture, 22 or ‘Twentytwo’ Bishopsgate stands  278 metres tall as the City of London’s tallest tower within the financial districts new ‘City Cluster‘. The tower provides over 1.2 million sq ft of office space and can accommodate up to four tenants on each of the 62 floors.

Over 17,000 tonnes of superstructure structural steelwork and metal decking was designed and fabricated for construction by Severfieldwho approached Farrat during fabrication to supply a suitable solution to mitigate against thermal bridging between connections.

Superelevations, axial shortening and complex geometrical dilemmas presented challenges on this project, so Farrat worked closely with Severfield to manufacture a package of structural thermal breaks in various sizes, shapes and thicknesses to fit seamlessly into design details and meet specification.

Farrat’s load-bearing structural thermal break material with the highest levels of compressive strength and thermal insulation, was used between steel-to-steel connections to prevent thermal transfer from the exterior of the structure into the internal structure via the steel framework.

Farrat thermal break plates were also used in steel-to-concrete applications to greatly reduce heat loss into the concrete slab, providing better insulation for the structure overall.

22 Bishopsgate during construction with Farrat Thermal Break in-situ, courtesy of Severfield
22 Bishopsgate during construction with Farrat Thermal Break in-situ, courtesy of Severfield

For in-depth technical information on all our grades of thermal break materials, please head over to our Thermal Breaks page, or alternatively you can contact us.

‘Twentytwo’ Bishopsgate is due for completion later this year.


Farrat’s BBA certificated structural thermal break materials provide building design professionals with a robust solution to minimise energy loss. Suitable to mitigate against planar, linear and point load thermal bridging, Farrat thermal breaks can be used anywhere a penetration or transition exists in a building envelope to help achieve building performance standards. Performance characteristics include low thermal conductivity, high compressive strength and very limited creep under load.

Full specifications are available for import from NBS Plus.

Farrat supply facade thermal breaks for new flagship Adidas store

Farrat thermal breaks used to thermally isolate the facade retention steelwork at new Adidas store

A joint venture between Grosvenor Britain & Ireland and Stow Capital Partners, the 425 Oxford Street retail scheme involves the reconfiguration and extension of the lower five floors of a 10-storey building in the West End shopping district, to create a 45,000 sq. ft flagship unit for Adidas.

The redevelopment features new double-height windows on the ground floor and an extensive glass frontage.

To prevent heat loss through the building facade, Farrat have supplied Structural Thermal Breaks for use within the facade retention steelwork. The facade thermal breaks will act as a thermal insulator and avert thermal or cold bridging.

This is a simple, economical and extremely effective solution to meeting Building Regulations by way of reducing the risk of internal condensation.

Farrat Structural Thermal Breaks can be used in a wide variety of applications where there is a structural requirement of thermal insulation, including:

  • Steel to steel
  • Steel to concrete / masonry
  • Steel to timber
  • Concrete to concrete

 

A full list of typical applications can be found here.


Handover of the bespoke scheme to Adidas is targeted for Spring 2019.

For material properties, design advice and specification details for Farrat Structural Thermal Breaks, please click here.

Farrat assist Arup in developing a structural thermal break suitable for latest redevelopment in Fitzrovia, London

80 Charlotte Street is the transformation of 1960s single-use blocks into a fully integrated development in Fitzrovia, London.

80 Charlotte Street, Fitrovia - image courtesy of Make Architects

80 Charlotte Street, Fitzrovia – image courtesy of Make Architects

The redevelopment will include an upgrade to interiors, adding new upper-floor extensions and three new atria above roof level. The finished scheme will be a mix office, residential, retail and public space and aims to achieve an environmental rating of ‘Level 4’ under the Code for Sustainable Homes.

Farrat assisted Arup in developing a structural thermal break suitable for use between the primary floor beam and column connections.

Understanding the structural requirement of thermal insulation on this project was crucial, and Farrat were able to engage with the designers in the early stages of the project. Farrat manufactured precision-cut Structural Thermal Breaks from our highest-strength material in accordance with the bespoke requirements of the customer, the BBA Quality Plan, ISO 9001 and ISO 14001.

The Structural Thermal Breaks were supplied with a Certificate of Conformity in accordance with our British Board of Agrément (BBA) Certification.  The BBA standard is a mark of quality and ensures that designers and clients have confidence in a product which is used in structural connections.

Farrat selected to supply Structural Thermal Breaks for The Post Building, London

The Post Building - render courtesy of AHMM Arhcitects

Courtesy of AHMM Architects

The Post Building is a mixed-use redevelopment of the former Royal Mail Sorting Office, located in London’s vibrant Knowledge Quarter.

A combination of carefully curated office, retail and food & beverage amenities, the redevelopment was designed by AHMM Architects and is currently being delivered by Laing O’Rourke. The lower half of the existing frame is retained and a new core and series of intermediate mezzanine levels will be inserted into the centre of its plan. Key structural features include floor to ceiling heights of up to six metres, natural light from all sides and private roof terraces to every floor.

The project targets sustainability ratings of BREEAM Excellent, LEED® Gold and EPC B by incorporating specialist materials and technologies into the design that promote the health and comfort of building occupants and improve building performance.

Farrat were approached early in the construction by the steelwork fabricator to supply structural thermal breaks for use between several connections within the structural frame.

Farrat Structural Thermal Breaks are incorporated into connections to reduce energy loss and the risk of condensation. They are frequently used as thermal insulators within many building applications to improve the energy performance of buildings.

We recommended our high-strength TBK Structural Thermal Break material, as this offers the lowest thermal conductivity and is certificated by the British Board of Agrément (BBA). Farrat is also a member of BRE’s Certified Thermal Product Scheme. Plates of various sizes were precision cut at our UK manufacturing facility and dispatched to site.

The Post Building is due for completion in 2018.

For material properties, design advice and specification details for Farrat Structural Thermal Breaks, please click here.

Farrat Structural Thermal Breaks used to isolate eight-storey steel-framed office block targeting ‘WELL Building Gold Standard’

‘Duke Street’ is an eight-storey office development, which forms part of the much wider St James’s redevelopment – a major 10-year investment programme that will revitalise the renowned central London area with a new public square, offices, retail outlets and high quality residences.

The building will provide 3,234m² of office accommodation, spread over six upper floors with two levels of retail offering 1,034m² of space. The project aims to achieve BREEAM ‘Outstanding’ for its commercial floors, BREEAM ‘Very Good’ for its retail zone, and as a whole, is targeting a WELL Building Gold Standard rating for its shell and core. The latter certification recognises the building has been designed as a healthy and productive space for its future occupants.

Farrat were approached by the Steelwork Contractor to supply thermal breaks to sit between steel connections within the structure. The building’s substructure is formed with concrete, and the main steel frame begins at basement level one, with the majority of the steel frame’s connections via fin plates. The thermal breaks were required to act as thermal insulators within the frame, to reduce the risk of thermal bridging and internal condensation.

Our high-strength Structural Thermal Break material was selected, offering the optimum combination of Compressive Strength and Thermal Conductivity. The plates were then precision-cut to the bespoke length, width and hole configurations required.

32 Duke Street - courtesy of New Steel Construction
32 Duke Street - courtesy of New Steel Construction

Duke Street is due to complete in Spring 2019.

For more information on the WELL Building Standard, download the guide here.

For material properties, design advice and specification details for Farrat Structural Thermal Breaks, please click here.