{"id":523113,"date":"2025-07-08T12:36:15","date_gmt":"2025-07-08T11:36:15","guid":{"rendered":"https:\/\/www.constructionnews.co.uk\/?p=523113"},"modified":"2025-07-18T12:56:57","modified_gmt":"2025-07-18T11:56:57","slug":"paragon-estate-tackling-modulars-biggest-safety-fix","status":"publish","type":"post","link":"https:\/\/www.constructionnews.co.uk\/project-reports\/paragon-estate-tackling-modulars-biggest-safety-fix-08-07-2025\/","title":{"rendered":"Paragon Estate: Tackling modular\u2019s biggest safety fix"},"content":{"rendered":"
\n

Client:<\/strong> Notting Hill Genesis
\nProject value:<\/strong> \u00a372m
\nContract type:<\/strong> JCT
\nScaffolding:<\/strong> Sean Doyle Scaffolding
\nElectrical:<\/strong> Giles & Giles
\nRoofing:<\/strong> The TP Group
\nSprinkler installation:<\/strong> Triangle Fire Systems
\nFirestopping:<\/strong> R Lewis and Co
\nMEP design:<\/strong> SJS Engineering
\nFull contract signed:<\/strong> March 2023
\nExpected handover:<\/strong> June 2026<\/p>\n<\/div>\n

The Paragon Estate never really lived up to its name. When it was built in 2006, there was real promise that the west London student accommodation scheme would be a milestone in high-rise volumetric modular building. Caledonian Building Systems built the six-block development, including the 17-storey Paragon Tower \u2013 at the time the UK\u2019s tallest modular building \u2013 in just 100 weeks, shaving months off the typical timeline for projects of its scale.<\/p>\n

But fewer than two decades later, the estate is deserted. Hundreds of residents were suddenly evacuated in late 2020, when repair contractors uncovered critical building safety defects. Caledonian Building Systems (later Caledonian Modular) became insolvent two years later. The government launched an investigation two years ago over its work on a series of schools.<\/p>\n

This pioneering modular development has now become a pioneering remediation project. Equans has the job of making the estate safe enough to live in. Its task is much more than patching up some botched workmanship \u2013 this is the first deep structural remediation of a volumetric modular high-rise building in the UK.<\/p>\n

\u201cPeople didn\u2019t really understand modular construction when [the Paragon estate] was first built,\u201d says Equans divisional manager Peter Banks. \u201c[There was] an insatiable requirement for modern methods of construction (MMC), to expand the rate of building. And you\u2019ve now got a lot of buildings designed without any knowledge of how they would perform.\u201d<\/p>\n

In the months and years after the Paragon Estate was evacuated, critical concerns about the safety of volumetric modular emerged. At the end of 2022, the National Fire Chiefs Council said in a statement that it lacked confidence that MMC projects faced enough scrutiny over build quality. It warned of \u201cdevastating\u201d consequences should a high-rise modular building collapse in a fire.<\/p>\n

Two years later, two government-commissioned reports flagged up the risk of fire spreading in gaps between modules. \u201cAll of the risks [that researchers] found on other jobs, we\u2019ve seen here,\u201d says Banks, who suggests the issues might be \u201cquite endemic throughout modular construction\u201d.<\/p>\n

Uncovering problems<\/h3>\n

The Paragon Estate flanks the Chiswick Flyover, greeting drivers with a curtain of scaffolding and blue gauze. Equans is remediating five student accommodation buildings and a shorter 179-home block to the site\u2019s rear \u2013 some 30,000 square metres of floorspace in total. The firm is also upgrading a squat circular hub building at the site\u2019s centre, which it is currently in use as the team\u2019s staffroom.<\/p>\n

Signs of trouble first emerged in 2017. During post-Grenfell safety checks, estate owner Notting Hill Genesis discovered cladding issues with missing fire breaks and cavity barriers. The housing association priced the recladding works at \u00a38m and put the job out to tender.<\/p>\n

Worse was to come. Once maintenance contractor Axis started taking down the cladding, it uncovered deeper structural issues. Notting Hill Genesis made the tricky call to evacuate more than 850 residents \u2013 mostly students \u2013 on a Monday morning at the height of the Covid pandemic.<\/p>\n

Then came another tough choice: demolish or refurbish? Having considered timeframes, cost and safety, the housing association opted to remediate. It initially put the remediation job out to competitive tender in summer 2021. But as the scale of risks became clearer, it turned to Equans, a firm it had worked with on other building-safety projects. The two firms reached an early works agreement in January 2022.<\/p>\n

Caught on camera<\/h3>\n

It wasn\u2019t until the pre-construction services agreement\u00a0 was signed in May 2022, allowing Equans to carry out more intrusive surveys, that the scale of the estate\u2019s dysfunction became clear.<\/p>\n

Equans stripped some of the facades and made around 4,000 openings to assess the state of the cavity barriers, which had been installed between modules in 11-metre linear runs. The team located these runs using existing drawings, then cut circular discs in the floor in three or four locations along each run and dropped cameras in to assess their condition. They found that 80 per cent of cavity barriers were non-compliant.<\/p>\n

Firestopping lacked adhesive on both sides of the firestops and coating on the screws. The seals were the wrong depth.<\/p>\n

One of the student buildings was somehow three inches out of plumb. \u201cYou\u2019d think with modular construction, with one module on top of the other, it would be almost impossible to get out of plumb,\u201d Equans operations manager Nick Wells says. \u201cIf I knew why, I\u2019d probably be a very rich man.\u201d<\/p>\n

In March 2023, Equans told Notting Hill Genesis how much these issues would cost to fix: \u00a372m, nine times that of the original tender price. The cost reflects how much of Equans\u2019 work at the estate is uncharted territory. \u201cThis wasn\u2019t a brick or concrete frame, where everyone knows how it performs from a structural or fire perspective. These types of building, we\u2019re still learning,\u201d says Banks.<\/p>\n

Search for test data<\/h3>\n

Equans found it could not fulfil the linear route to compliance, so instead it is taking the approach outlined in the BS 7974 framework, which models a whole fire event with fire locations and management responses. \u201cWe work out solutions, test them, test them again when they fail,\u201d says Banks. \u201cThe guiding question has been \u2018What if that fails?\u2019\u201d<\/p>\n

The team also discovered that firestopping testing standards designed for conventional construction were unsuitable for modular buildings. According to those performance criteria, the unexposed face of a wall is tested to measure how quickly fire spreads through it \u2013 but modular buildings also have structural elements within the walls that can be damaged by fire.<\/p>\n

\u201cThere was just no test data,\u201d says Wells. \u201cWe had to dig deep into the archives to find out what had been done before.\u201d They performed seven bespoke fire tests for different components of the building.<\/p>\n

Cavity barriers were completed by May 2024, which Banks calls a \u201cwatershed\u201d moment in bringing the building back into use. \u201cWith other jobs where fire broke out, it\u2019s breached a compartment line and then there\u2019s no way of tracking where fire and smoke spreads,\u201d says Banks. \u201cOne of the real conundrums of this job was to solve how we deal with [the fire compartmentation] without taking down the building.\u201d<\/p>\n

Although some of the cavity barriers were still fit for purpose, Notting Hill Genesis directed Equans to replace them all, for peace of mind. Within the voids, Equans installed Injectaclad, an acrylic-based graphite sealant that expands when hot. When tested, the material resisted fire for triple the amount of time required by building regulations.<\/p>\n

The existing cladding and insulation not only posed a fire hazard \u2013 they also provided little protection against the drab London weather. Consultancy WSP identified significant thermal bridging across the uninsulated steel pods, causing internal surface condensation and considerable heat loss through the envelope. Residents had complained to Notting Hill Genesis about the damp, and some of the internal stud walls were stained with mould.<\/p>\n

\u2018Big game of Tetris\u2019<\/h3>\n

New cladding therefore had to serve the double purpose of making rooms safe and thermally comfortable. After analysing the risk of condensation and calculating proposed U values, Equans proposed replacing the original terracotta panels with an aluminium system, powder-coated in a similar colour. Reducing the weight of panels allowed the building to take 100m mineral wool insulation, improving its thermal qualities.<\/p>\n

Each block had been insulated with 9mm combustible plywood OSB, which provided some of the building\u2019s lateral strength at the lower levels. Wells compares removing and replacing the boards one by one to a \u201cbig game of Tetris\u201d.<\/p>\n

Equans removed the 90mm EPS render system used on two of the blocks, replacing it with aluminium panels with a Sto render finish, encapsulating 130mm mineral wool insulation board. U-values will now range between 0.2 and 0.3 depending on wall build-up, down from an average of 0.73 across the development.<\/p>\n

The first three student blocks will be handed over this summer. The remaining buildings, including Paragon Tower, are due to complete the following June. Banks says: \u201cUltimately, when people move in, we can leave this job with a clear conscience, knowing we\u2019ve done everything reasonably practicable to keep them safe.\u201d<\/p>\n

\n

Paperwork stacks \u2018as high as the building\u2019<\/h3>\n

Reflecting the stakes of the job, the client has employed two clerks of works. Equans has supplied plenty of documentation to keep them busy \u2013 hundreds of surveys, design notes and assessments. \u201cWe did 23 revisions of a technical document just for remediating the doors,\u201d says Equans operations manager Nick Wells. \u201cWhen the paperwork stacks as high as the building, that\u2019s when it\u2019ll be ready to be occupied.\u201d<\/p>\n

Every time something is removed from or added to one of the buildings, Equans takes a photo and logs it in cloud-based mobile app Field View. Each elevation is split up into 2-metre by 2-metre grid lines, allowing anyone working on the building in the future to pinpoint the location of any issues that arise.<\/p>\n

The firestopping is logged in Boris, a similar piece of software. \u201cWe must have thousands and thousands
\nof photographs,\u201d says Wells.<\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

Client: Notting Hill Genesis Project value: \u00a372m Contract type: JCT Scaffolding: Sean Doyle Scaffolding Electrical: Giles & Giles Roofing: The TP Group Sprinkler installation: Triangle Fire Systems Firestopping: R Lewis and Co MEP design: SJS Engineering Full contract signed: March 2023 Expected handover: June 2026 The Paragon Estate never really lived up to its name. …<\/p>\n","protected":false},"author":141524,"featured_media":523118,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"ep_exclude_from_search":false,"footnotes":""},"categories":[559,557],"tags":[],"class_list":["post-523113","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-long-reads","category-project-reports"],"yoast_head":"\nParagon Estate: Tackling modular\u2019s biggest safety fix | Construction News<\/title>\n<meta name=\"description\" content=\"Client: Notting Hill Genesis Project value: \u00a372m Contract 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