{"id":494388,"date":"2024-03-18T12:55:38","date_gmt":"2024-03-18T12:55:38","guid":{"rendered":"https:\/\/www.constructionnews.co.uk\/?p=494388"},"modified":"2025-06-27T14:51:20","modified_gmt":"2025-06-27T13:51:20","slug":"east-side-story-proving-the-potential-of-volumetric-construction","status":"publish","type":"post","link":"https:\/\/www.constructionnews.co.uk\/project-reports\/east-side-story-proving-the-potential-of-volumetric-construction-18-03-2024\/","title":{"rendered":"East side story: proving the potential of volumetric construction"},"content":{"rendered":"

A project in Walthamstow is proving just how far volumetric modular construction can go, with 75 per cent of two new towers being built offsite<\/strong><\/em><\/p>\n

\n

Project client:<\/strong> Long Harbour
\n<\/span>Contract value:<\/strong> \u00a3165m
\n<\/span>Contract type:<\/span> <\/strong>JCT design-and-build
\nMain contractor:<\/strong> <\/span>Tide Construction Ltd
\nOffsite manufacturer:<\/strong> <\/span>Vision Modular Systems
\nArchitect:<\/strong> <\/span>Assael Architecture
\nStructural engineering:<\/span><\/strong> Barrett Mahony Consulting Engineers \/ MJH Structural Engineers
\nReinforced concrete frame\/core\/groundworks:<\/strong> OBR
\n<\/span>Demolition:<\/strong> <\/span>Embassy Demolition Contractors
\nPiling:<\/span><\/strong> Murphy Ground Engineering
\nMechanical, electrical and plumbing:<\/strong> Red Group
\n<\/span>Facade contractor:<\/strong> Century Facades
\n<\/span>Construction start date:<\/strong> January 2023
\n<\/span>Expected handover:<\/strong> March 2025<\/span><\/p>\n<\/div>\n

In its latest report, the House of Lords\u2019 Built Environment Committee criticised a lack of progress in the UK\u2019s adoption of modern methods of construction (MMC), arguing that the sector lacks coherent government support and measurable objectives.<\/p>\n

High-profile failures in the past two years suggest pitfalls in the MMC business model, but with the right approach from the public and private sectors, there is no reason why modular solutions can\u2019t play their part in solving the UK\u2019s housing crisis. <\/span><\/p>\n

In Walthamstow, for example, specialist modular contractor Tide Construction is using a volumetric approach to build phase one of The Mall, comprising 495 build-to-rent flats, for client Long Harbour, which acquired the site from real estate investment trust Capital & Regional (C&R) in December 2020. Selborne One and Selborne Two \u2013 a pair of now-dormant C&R subsidiaries \u2013 obtained planning permission in January 2021 for a two-phased redevelopment of the site. Phase one\u2019s construction of two residential towers will be followed by the expansion of the existing 17&Central shopping centre in phase two, for which C&R hasn\u2019t yet chosen a contractor. Together, both phases will occupy a 2,700 square metre footprint.<\/span><\/p>\n

Tower A rises 34 storeys and 116 metres while its neighbouring Tower B is 27 storeys at 92 metres. They will contain a combined 1,375 modules once completed: a mix of bedrooms, bathrooms, kitchens and living rooms manufactured in Bedford by Tide\u2019s offsite subsidiary Vision Modular Systems (VMS). Some 75 per cent of the project will be constructed offsite, but not only by VMS. The communal staircases, for example, are being made by Peterborough-based Stair Master.<\/p>\n

Tide is no stranger to the volumetric scene. It claims to have constructed seven of the 10 tallest modular buildings in the world, its highest being College Road in Croydon (163 metres, completed last year). However, the Walthamstow scheme is the first modular project commissioned by Long Harbour, which awarded Tide a \u00a3165m contract
\nin July 2022.<\/p>\n

\u201cIf you came here two years ago, this site was just a yard with old retail units, some bins and not much else,\u201d says Tide project director Richard Kennedy. Embassy Demolition Contractors worked for Tide in an enabling works package, which included foundation and piling works plus the separation of services between the live shopping centre and the phase one site.<\/p>\n

Tower B sits above a Tube line, so Tide needed design-stage engagement and approval from Transport for London before piling subcontractor Murphy Ground Engineering was free to drive a total of 240 piles into the ground to an average depth of 28 metres. Murphy used a continuous flight-auger piling technique, says Karl Roulstone, the firm\u2019s preconstruction lead. With piling work completed, Tide built the cores for both blocks above basement level.<\/p>\n

Onsite activities included batching and pouring of the reinforced concrete (RC) centralised core shaft and frame for each building, carried out by groundworks and RC contractor OBR Construction under a \u00a39m subcontract. The frame functions as a transfer structure to redirect the vertical loads. It goes up to the third storey on each building and the core rises above it.<\/p>\n

Before implementing the RC frame, OBR also conducted groundworks such as underground drainage, underground services, waterproofing and foundations. The slipformed core for each building was implemented at a typical tempo of a floor a day, or 34 days of pouring for Tower A and 27 for Tower B. \u201cOn a typical day, we had 10 concrete wagons arrive on site when we were pouring the core,\u201d says Kennedy. Each wagon contained 7.5 cubic metres, meaning 75 cubic metres of concrete was poured per day.<\/p>\n

Fast timetable<\/span><\/h3>\n

Tide is delivering modules at a steady pace and to a fast timetable, with all flats set to be installed within a 21-week window that opened in September 2023. The contractor calculates that a traditional construction approach would have taken 98 weeks. \u201cOn each floor in both buildings there are 25 modules,\u201d says Tide and VMS chief executive Christy Hayes. \u201cEach week we install 65 modules. That\u2019s the equivalent of two-and-a-half floors per week.\u201d<\/p>\n

Kennedy says all volumetric units are watertight before leaving the factory, including rainscreen cladding for the external walls. \u201cThe modules come with the internal wall already installed,\u201d he adds. Once on site, the units are craned into place and stacked vertically on top of the frame and around the RC core in each tower. Tide then completes the final connections, commissioning and external, non-combustible facade system, including all fire-barrier compartmentation. <\/span><\/p>\n

Steel connectors link the modules vertically and laterally at specific points to one another and to the RC core for structural stability and minimal differential movement. Tide construction director Darren Twomey says: \u201cWe cast plates when we were building the concrete core that tie each module horizontally onto the core when it\u2019s lifted into place.\u201d <\/span><\/p>\n

Site logistics could have posed a headache, as The Mall is sandwiched between a rail line to the south over a busy main road, and the shopping centre directly to the north. In addition, Walthamstow Central station is just 160 metres to the east. But the volumetric method scores big for logistical efficiency. Each module is transported almost 50 miles by road from the VMS factory in Bedford to the roadside next to the two under-construction towers. \u201cAll we need to install modules is a parking bay,\u201d says Kennedy. <\/span><\/p>\n

On its visit, Construction News<\/i> witnesses the process in action. A module (in this instance a fully fitted kitchen) arrives on a flatbed truck, is picked up by one of two tower cranes provided by Laing O\u2019Rourke subsidiary Select Plant Hire. The 12-metre-high cranes are installed atop the central structural core on each building, and modules are lowered into place in 10-15 minutes. <\/span><\/p>\n

Twomey says Tide created a detailed cranage strategy for the project that includes a VMS-designed lifting frame that prevents the cranes from obstruction as they place the modules. \u201cEach volumetric unit has designated lifting points that allow the unit to be safely lifted [from the roadside] and installed with precision tolerances,\u201d he notes.<\/p>\n

The modular units weigh an average of 20 tonnes and arrive onsite with 80 per cent of their interior fittings already in place. The cranes will remain onsite until all the modules are installed, and they will be removed after the VMS-manufactured crown steelwork is installed on the roof of each tower. <\/span><\/p>\n

The 3-metre-high modules come in various widths and lengths (up to 4.7 metres and 10.3 metres respectively). Their installation takes place with minimal human involvement, says Hayes, and this helps to reduce site safety risks compared with traditional methods. \u201cYou can imagine, if this was a traditional build, the number of deliveries and tradespeople involved.\u201d He adds that traditional methods of construction for the two towers would require 450 to 500 site workers, whereas the onsite workforce is currently at peak activity with 110 staff. <\/span><\/p>\n

Among the workers on site are staff from Century Facades, who are installing cladding rails and glazed terracotta cladding on Tower A, working on the facade from double-stacked mast climber platforms. The terracotta material is made in Germany by NBK. Aluminium-framed windows from Reynaers are installed offsite by Century.<\/span><\/p>\n

Backbone mechanical, electrical and plumbing (MEP) works are provided by specialists from Red Group. There are fewer onsite MEP requirements than with a conventional build, as the modules arrive with lighting, pipework, sockets and even electric appliances pre-installed in the factory. \u201cOnce installed, the MEP within the volumetric units is connected and commissioned to the central MEP within the building,\u201d Twomey explains. He adds that the overall production, delivery and installation process means the project is on course for handover to the client in March 2025, three months ahead of schedule \u2013 rare for a construction job. <\/span><\/p>\n

Asked why more firms can\u2019t implement rapid-tempo projects, Hayes comments that the \u201cvertically integrated\u201d nature of Tide helps to ensure a smooth construction process. \u201cWe\u2019re developers, contractors and offsite manufacturers,\u201d he says. \u201cI think maybe where [other] models fail is where the main contractor and modular supplier are different companies and may not understand totally how the whole building comes together.\u201d<\/p>\n

So how far can offsite construction go? \u201cYou\u2019ll always have to do certain things on site: the foundations, roofing, lifts, and a certain amount of backbone MEP,\u201d says Hayes. \u201cBut I think we can get to a position [in future schemes] where we can peak at around 95 per cent offsite manufacturing.\u201d <\/span><\/p>\n

\n

Chasing the green dream<\/span><\/h3>\n

Tide and VMS chief executive Christy Hayes argues that the time, labour and cost efficiencies inherent in the firm\u2019s methods also bring environmental benefits, with lower overall emissions and minimal noise disruption for nearby residents and businesses.<\/p>\n

He cites separate studies from the University of Cambridge and Edinburgh Napier University that Tide\u2019s buildings contain 45-50 per cent less embodied carbon than traditional methods, although he wants the firm\u2019s sites eventually to be zero carbon.<\/p>\n

\u201cWe\u2019re using in-depth studies from Cambridge to write a toolkit for assessing modern methods of construction in relation to embodied carbon, but also to identify and target the biggest offenders from a carbon-footprint perspective,\u201d Hayes says, adding that Tide is also providing the Cambridge researchers with historical and real-life energy-consumption and operating-cost data on its completed buildings.<\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

A project in Walthamstow is proving just how far volumetric modular construction can go, with 75 per cent of two new towers being built offsite Project client: Long Harbour Contract value: \u00a3165m Contract type: JCT design-and-build Main contractor: Tide Construction Ltd Offsite manufacturer: Vision Modular Systems Architect: Assael Architecture Structural engineering: Barrett Mahony Consulting Engineers …<\/p>\n","protected":false},"author":135716,"featured_media":494416,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"ep_exclude_from_search":false,"footnotes":""},"categories":[557],"tags":[],"class_list":["post-494388","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-project-reports"],"yoast_head":"\nEast side story: proving the potential of volumetric construction | Construction News<\/title>\n<meta name=\"description\" content=\"A project in Walthamstow is proving just how far 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