Modern Methods of Construction Archives | UKGBC /focus-areas/modern-methods-of-construction/ The voice of our sustainable built environment Tue, 04 Nov 2025 11:34:33 +0000 en-GB hourly 1 /wp-content/uploads/2023/02/cropped-UKGBC-favicon-1.png Modern Methods of Construction Archives | UKGBC /focus-areas/modern-methods-of-construction/ 32 32 Coating to increase the efficiency of photovoltaic cells /resources/coating-to-increase-the-efficiency-of-photovoltaic-cells/ Fri, 10 May 2024 14:29:09 +0000 /?post_type=resource&p=58494 Superhydrophobic, antireflective coatings to improve PV efficiency by reducing reflections and repelling dust and dirt

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Problem Addressed

When considering energy lost to solar reflectance and efficiencies, % of the solar energy available. This loss due to reflectivity and environmental conditions can be counteracted through the use of anti-reflective and anti-static coatings.

Solution Overview

Window Insulation’s Solar Enhancer Coating is designed to enhance the efficiency of solar panels. The coating minimises the reflection of the solar cells, improving efficiency, and the cells’ ability to self-clean and degrade the pollutants. Its anti-static properties enable the layer to actively repel dust and dirt. The superhydrophobic, antireflective coatings show self-cleaning, anti-dust, antipollution, anti-icing, and antifogging features. All of this can lead to an improvement of efficiency of the solar cells.

This is the 4th version of the product which uses graphene. This version is planning to undergo third-party testing in a specially equipped solar facility in Germany. Additionally, the product has been undergoing independent testing with both the Swiss and Italian Government. There has been testing done on the previous version of the solution by various universities which shows the coating can improve the PV yield by 20-30%.

The coating works by providing the PV panel with a thin, transparent, hydrophilic coating layer. The photocatalyst element of the coating is activated by sunlight and forms a reactive oxygen species (ROS), this ROS reacts with organic material like microbes and VOC-compounds found on surfaces.  This causes the microbes and VOCs to decompose, with the oxygen compounds reacting with water and carbon dioxide and being neutralised. Durability testing indicates that the coating has a demonstrated durability of more than 10 years, with newer versions expected to last between 10-15 years before reapplication is required.

Case Study

A study held from October 2017 to February 2018 compared a series of 18 PV panels coated with Window Insulation’s Solar Enhancer coating to five strings (18 panels each) with no coating to be used as a control group. Over those five months, the PV panels with the Solar Enhancer showed an average efficiency increase of 10.635%. These increases can also be as high as 20-30%. Currently, Window Insulation’s Solar Enhancer has been installed on over 10 million square meters of solar panels globally.

Facts and Figures

10.6 %
10,000,000+ m2

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Community led approach to building affordable housing on micro-sites /resources/community-led-approach-to-building-affordable-housing-on-micro-sites/ Thu, 18 Apr 2024 14:48:32 +0000 /?post_type=resource&p=58041 Framework to build social infrastructure and community wealth while providing homes where they are needed.

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Problem Addressed

The current housing crisis in the UK requires innovative solutions. According to , the council house waiting list is longer than ever before with over 1.2 million households registered. Many of these households remain on the list for over five years due to a lack of supply. Consequently, housing prices are unaffordable with the report stating that full-time employees in England must spend 8.3x their annual earnings to buy a home. Of the homes that are being built, only 2% delivered in England and Wales in the second quarter of 2021 were built to the highest energy efficiency standards.

Solution Overview

WeCanMake have developed a framework for addressing these problems which can build social infrastructure and community wealth all the while providing homes where they are needed. The framework was developed on a neighbourhood test-space in Knowle West, Bristol, a 100-year-old council-built estate. WeCanMake is a community land trust (CLT) which has developed a community-led and innovative approach to build affordable homes in micro-sites. Landowners can opt-in to provide micro-sites to be used for new homes. These sites could be between existing buildings or in large back gardens. WeCanMake’s strategy is focused on what they call ‘gentle densification’ which involves utilising the capacity of the existing urban fabric instead of building in greenfield areas or with high-rise housing complexes.

Ownership of the micro-sites is transferred from the Council to the CLT to be held by the Trust in perpetuity giving low density neighbourhoods the power to densify on their own terms. Through the CLT, the community also establishes a Community Design Code to ensure that any new homes add to the neighbourhood’s character and are high-quality. Their Our Living Rent policy also ensures that rent for the new homes is no higher than one-third the average neighbourhood household income. WeCanMake also utilises Modern Methods of Construction to realise a number of benefits. This approach allows for the homes to be locally produced in a community microfactory, ensuring that the community can retain more value by locally developing skills, creating jobs, and providing tech infrastructure.

WeCanMake’s framework was also developed to function without requiring any new policy or regulation. It can function as a prototype for similar communities across the UK. With many similar neighbourhoods in other cities, the approach WeCanMake has developed can be scaled, replicated, and adapted elsewhere. To facilitate this, they have published their Playbook to explain their methods and share insights into how it could be applied in other communities. Over 1.1 million council-built interwar homes like those found in Knowle West can be found across England. With only a 3% increase in densification, 33,000 affordable homes could be built where they are needed most.

Case Study

In Knowle West, WeCanMake has already built two community-led, locally made, Living Rent homes one of which is a 2-bedroom single storey home built for a young family. The home was constructed using a BlokBuild OSB timber cassette system and is 100% electric with solar panels and an air source heat pump. Toni, one of the residents, was involved early on in every stage of the planning and design of her home. She was able to assist in the fabrication at WeCanMake’s community micro-factory and worked on site to complete the home.

Facts and Figures

2 homes
33,000
1/3

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Bio-based Prefab Modular Building System /resources/biobased-prefab-modular-building-system/ Tue, 17 Oct 2023 09:05:22 +0000 /?post_type=resource&p=53118 Sustainable construction system using modular biobased wall, roof, and floor panels.

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Problem Addressed

The published by IEA found that the manufacturing of building components and materials is responsible for 11% of global carbon emissions. These emissions are a significant proportion of the built environment’s embodied carbon. When also factoring in operational carbon and the substantial amount of waste generated by the construction industry, the materials and methods we use to construct our cities and homes must be radically reimagined to reduce the environmental impact that buildings currently incur.

Solution Overview

Natural Building Systems has developed a construction system made with biogenic materials to address embodied emissions, operative emissions, and the waste associated with construction. Their system includes lightweight, breathable insulated wall, roof, and floor panels, which are standardised and designed to be efficiently assembled on site and easily disassembled and reused. Natural Building Systems’ primary innovation is the integration of HempSil, a natural insulation made from hemp, with demountable structural cassettes. During its growth, hemp absorbs up to 14 tonnes of carbon per hectare annually and is a good crop to incorporate into sustainable field rotation strategies. When used as an insulation material, hemp absorbs and desorbs moisture in the air, regulating indoor relative humidity and temperature.

The system is also well suited to address other problems typically attributed to the built environment. The panels themselves are self-similar to reduce costs and waste during production, but they can be combined with each other and bespoke components to provide a great amount of flexibility in design. Natural Building Systems’ panels can be delivered flat-packed or pre-assembled depending on the project needs. Assembly and disassembly are both quick and easy due a patented method of securing panels together using timber pegs and T&G cones. This method also allows reconfigurations or alterations to be made without waste.

Natural Building Systems are committed to the circular economy and even provide BIM material passports for all their products. Currently, this system is limited to 11m high buildings for residential use in the UK, but for non-residential uses it can be used for structures up to 8 stories high when paired with a timber structure.

Case Study

Green Light Trust (GLT) provide training and support for people suffering mental illness, near woodlands and forestry environments. Natural Building Systems were commissioned to design and manufacture the wall and roof elements for a new building, in an under-used car park adjoining woodland near Martlesham, owned by Suffolk County Council. The 100m2 scheme is comprised of two separate buildings linked by an external walkway. One half will serve as a training facility while the other, offices for GLT. Having already obtained planning permission, Natural Building System worked closely with the client’s team to optimise the design to deliver a breathable, low-embodied carbon, circular solution.

The building was partially completed in August 2023 and GLT are now fundraising to finish internal works including MEP services. The alignment in values between Natural Building Systems and Green Light Trust was manifest in the use of entirely natural, regenerative materials to create a high performing, healthy building.

Excluding biogenic carbon, the whole building LCA for A1-A5 is provisionally estimated at only 219kg Ce/m2 pending completion of the fit-out works. Due to the use of primarily natural materials, the biogenic carbon captured during their production accounts for 1.36 tonnes Ce/m2. The superstructure of the building uses entirely natural regenerative materials and is built with pre-manufactured components to allow for disassembly and adaptation. GLT’s focus on Whole Life Cycle carbon impacts (rather than simply operational carbon) informed a design that limited U Value targets in the building’s roof, walls, and floor to 0.18W/m2K, 0.2W/m2K, and 0.18W/m2K respectively while the estimated Energy Use Intensity (EUI) is estimated at 60kWh/m2 per year.

Additional information about this case study can be found at the link below.

Facts and Figures

£1,000 per m2

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Sustainable Structural Insulated Panels /resources/sustainable-structural-insulated-panels/ Mon, 09 Oct 2023 13:56:34 +0000 /?post_type=resource&p=52852 Insulation made from recycled plastic and organic materials.

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Problem Addressed

Bio-SIP™ addresses one of construction’s most pressing sustainability challenges – the environmental impact of traditional building materials.

With embodied carbon responsible for 20% of UK built environment emissions, it is imperative that construction materials are as sustainably sourced and reusable as possible. Some conventional insulation and structural systems rely heavily on carbon-intensive products such as concrete, steel, and petrochemical foams, which contribute to global CO₂ emissions and resource depletion. The industry also faces growing pressure to reduce waste and transition toward circular, low-impact materials without compromising performance or scalability.

Solution Overview

Bio-SIP™ is a sustainably sourced and high-performance SIP developed by Qube Buildings to make construction easier and more environmentally friendly. The panels themselves are composed of an insulation core made from 100% recycled PET plastic sourced from a reputable manufacturer, and a structural facing made from bio-based materials including hemp and waste products from sugarcane production. In total, the insulated panels are made from 99.5% recycled plastic and organic materials. While this does create a wall system that combines the biological and technical cycles, it is assembled without adhesives, allowing for easier disassembly. This means these components can be moved and reassembled or repurposed at end of life.

The Bio-SIP™ system is used to construct complete buildings or upgrade existing structures, forming the building envelop providing an all-in-one structural system. It can be applied across net-zero homes, modular buildings, extensions, leisure facilities, classrooms, garden buildings and affordable housing.

In terms of thermal performance, independent testing by the BBA recorded a thermal resistance of 1.377 ²/ at 100mm, and a 300mm panel achieves a U-value of 0.11 /², meeting PassivHaus standards for ultra-efficient construction.

Fire testing in accordance with EN 1365-1 demonstrated 52 minutes of structural fire resistance, with a reaction-to-fire classification of Class E. These results form part of the evidence base for Bio-SIP’s ongoing BBA certification process.

Manufacturing of Bio-SIP™ is planned to be micro-factory model, enabling scalable and decentralised production. Rather than relying on a single centralised facility, small modular micro-factories can be established close to markets, reducing transport emissions and stimulating local economies. Each micro-factory can produce Bio-SIP™ panels, assemble building kits, and support nearby construction partners, creating a network of regional sustainable manufacturing hubs. Initial calculation show the return on investment (ROI) for a Bio-SIP™ micro-factory is projected within 2–3 years, based on current sales forecasts and profit margins achieved in early small-scale projects. Once scaled, each factory can generate an estimated net profit of £150,000–£250,000 per annum, depending on production volume and local market conditions.

Case Study

Bio-SIPS were used for the construction of a garden building in Chiddingfold, Surrey. Due to the modular components used, the entire building arrived flat-packed on a single luton van. A team of three installers completed the whole project in only two days including the installation of ground screws as a foundation system. The finished garden building was used to store paints and chemicals, meaning the thermal stability provided by the panels was appreciated by the clients.

Facts and Figures

1.377 ²/
0.11
2-3 years

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Advanced battery system for construction projects /resources/advanced-battery-system-for-construction-projects/ Tue, 26 Sep 2023 07:23:45 +0000 /?post_type=resource&p=52465 An Energy Storage System (BESS) which provides diesel-free power for the next generation of construction projects.

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Problem addressed

The world is facing an urgent need for both urbanisation and decarbonisation. Heavy industries such as construction, largely powered by diesel, account for a large proportion of carbon emissions. The construction industry is lagging behind in technology, productivity, and sustainability with the race to electrification and renewable energy.

Solution overview

Available in various configurations, the Ampd Enertainer is designed for the tough, dynamic, and space constrained needs of construction sites. The Ampd Enertainer battery system has high power outputs, capable of meeting the most demanding of loads. This enables the use of zero or low carbon energy sources resulting in no direct “tailpipe” emissions and none of the harmful CO, CO2, NOx, PM or SO2 emissions of a diesel generator. The Enertainer can be used in areas with poor ventilation and is nearly 32 times quieter than a diesel generator reducing noise pollution in the local community. The Enertainer can replace most large diesel generators and be installed and ready for operation in under 2 hours.

The Ampd can either be supplied by on-site renewables, or trickle charged from the grid during times when the electricity is cleanest and cheapest. This also prevents large amounts of power being drawn in one go from electricity grids.

Internet connectivity enables remote monitoring, device management, remote troubleshooting, and data analytics for the users to understand site operations from anywhere, anytime. Furthermore, automatic recharging, few maintenance requirements, and a modular design means almost no downtime for site operations.

The Enertainer comes in three model sizes, and all have an expected lifetime of 10+ years.

Case study

Multi-welfare Services Complex

Four Enertainers Model “L” was used to power four 64-tonne tower cranes at a Modular Integrated Construction site in Kwu Tung, Hong Kong. Kwu Tung is a rural area with limited power supply, so the Enertainer solved this problem. By using the Enertainers, the project was able to save HKD854,000/year on diesel fuel cost and 495,865 kg annual carbon reduction with a 61% CO2 reduction. Furthermore, there was zero on-site air pollution resulting in better conditions for workers.

 

Facts and Figures

32 x
<2 Hrs
10+ Yrs

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Bio-based modular wall system made of timber and straw /resources/bio-based-modular-wall-system-made-of-timber-and-straw/ Tue, 04 Apr 2023 08:43:36 +0000 /?post_type=resource&p=45468 A construction system that brings sustainable and healthy living.

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Problem addressed

The built environment is directly responsible for 25% of UK emissions, lifting to 42% if you include surface transport. According to EcoCocon, over the lifetime of a building, materials alone make up to 49% of its overall carbon emissions.

Solution overview

EcoCocon is a modular system for building external walls. It consists of structural timber-straw panels, an airtight membrane, a layer of insulating fibre board and interior clay plaster. The system fulfils the highest quality requirements, including the German Passivhaus Standard. EcoCocon’s natural construction system makes the most of a bio-based and rapidly renewable resource – straw, while offering Passivhaus thermal performance, thus reducing the carbon footprint significantly over the whole life cycle of a building.

The panels are made of 98% natural renewable materials (10% timber and 89% straw) and are Cradle to Cradle certified. They were designed to have minimal ecological footprint and to be safely returned to nature after use. The wood comes from sustainable forestry, and the straw is sourced at local farms. Used in their raw states, the production process demands very little primary energy. Both materials sequester large amounts of CO2 through photosynthesis over their life. This CO2 is then safely stored in the construction until end-of-life which is expected to be 75 years according to their EPD.

A coat of allergy-free, non-toxic interior clay plaster passively regulates indoor humidity and helps to keep it at optimal levels. The entire system is permeable to vapour and with no thermal bridges and airtight, it leaves no space for draughts or mould. Natural materials create a healthier indoor microclimate with even temperatures – warm in winter and cool in summer. Exterior wood fibre layer protects the airtightness and helps to achieve the Passivhaus standard in cold climates.

EcoCocon panels are custom-made for each project. A whole building can be assembled in very little time compared to traditional construction. Installation of panels is a 100% dry and waste-free process.

The system has a U-value of 0.12 W/m^2K.

Similar to buying organic food, using healthier and more sustainable natural alternatives is always slightly more expensive compared to industrial products. The cost of a project built with the EcoCocon straw wall system varies and depends on many factors, such as location and building design. However, with optimal planning and implementation, such a project may cost approximately the same as a conventional build.

The true cost-efficiency comes in the form of additional benefits the solution brings. Thanks to straw’s excellent thermal performance, EcoCocon buildings are very energy-efficient, allowing for massive energy-related savings in the long run. Heating expenses in buildings built to the Passive House standard – which is easily achievable with EcoCocon – can be up to 90% lower compared to typical houses, according to the Passivhaus Institute.

The construction time is significantly lowered with easy and rapid installation of the modular system on site. The resulting buildings are of higher quality with low operating expenses and healthier indoor microclimate.

For more information about EcoCocon’s sustainability metrics, refer to their .

Case study

This first UK application of the EcoCocon straw wall system is a single storey detached home which sits snugly within its rural surroundings. The team persevered through a 4 year planning process resulting in an efficient, spacious, and simple self-build.

Old Holloway is a prime example of how natural materials, such as straw and wood, can be effectively used to reach the Passivhaus standard. The property’s highly-insulated walls constructed using timber-straw panels, ensure minimal heat loss, resulting in an extremely energy-efficient house. Moreover, the use of natural materials reduces the environmental impact of the construction process, while also providing a cost-effective solution for insulation. The result is a comfortable living environment for the owners, with minimal energy consumption and heating bills, making it a prime example of how sustainable housing can be both cost-efficient and environmentally friendly.

The prefabricated system allowed for rapid and precise construction. The external walls were erected in three days and the house was watertight in four weeks. The large south roof overhang, in combination with simple manual external blinds to the south-facing bedroom provides a simple way of minimising the risk of overheating. Each space has an openable window which can be left open on tilt-in overnight. Monitoring during the first 5 years confirmed 0% overheating. Conversely, the house requires very little heating even in a cold winter.

While modest in size and budget, Old Holloway is spacious thanks to the open cathedral ceiling. The house was built for a price comparable with a regular house, costs almost nothing to heat, and is a testament to what Passivhaus design and bio-based materials can achieve.

Old Holloway has been widely recognized for its success. The project has been featured in various media outlets and championed by the Passivhaus Trust.

Facts and Figures

98 %
0.12 W/m^2K

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Affordable, low carbon modular homes /resources/affordable-low-carbon-modular-homes/ Fri, 31 Mar 2023 10:13:25 +0000 /?post_type=resource&p=42377 Designing and Building truly affordable, modular, low carbon housing.

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Problem addressed

The UK construction and design industries will need to make a crucial adjustment in order to reach the UK Government’s pledge to reduce emissions to net zero by 2050 and the UN’s sustainable development goals. A focus on increasing building energy efficiency, providing onsite renewable energy and reducing embodied and operational carbon emissions in order to meet these ambitious goals is a must.

Solution overview

ZED PODS is a factory-built modular construction system that can be used to assemble residential or commercial buildings and is designed with an approach to holistically reduce carbon emissions and energy use. Developed and tested at the Building Research Establishments (BRE), this award-winning solution is the only product suited to be built on a steel podium above car parks with special considerations for fire, quality, noise, air quality and utilities.

The steel-framed modular construction system has been designed by ZED PODS in-house architectural team with a “fabric first” approach to reduce operational carbon emissions by minimizing thermal losses by conduction and infiltration. ZED PODS reduces the amount of energy lost when heat is transferred from inside to outside through specifying thick insulation build-ups, insulated floor slabs and thermally efficient triple-glazed windows and doors. A significant reduction in heat loss through the envelope by conduction is achieved with U-Values of less than 0.15W/m2.k for all elements and high attention to breaking thermal bridging. This is supported by robust, approved construction details and thermal breaks that reduce thermal bridging and create a more uniform retention of internal heat.

Each module is provided with a dedicated airtightness layer and careful attention is paid around openings by use of taping to prevent warm air from the inside from escaping via infiltration and convection. Furthermore, ZED PODS use mechanical ventilation that recovers more than 80% of the heat from expelled air. This allows a constant supply of fresh air to circulate without the natural heat loss of other ventilation methods and creates improved indoor air quality by reducing particulate matter and CO2 concentrations — while also increasing oxygen supply.

During the design of the projects, ZED PODS utilise simulation software to ensure that adequate daylight factors are created inside the spaces – reducing artificial lighting and increasing solar gains.

ZED PODS uses onsite renewable technologies to meet the energy demands once the build system has been designed and tested. Hot water and heating demand is met via their MVHR unit and a solar assisted heat pump, which have no gas connections. The remainder of the energy need is met by roof-mounted photovoltaic panels, which offsets the remaining carbon emissions and results in a zero operational carbon scheme.

The cost to build ZED PODS’ scheme is £2,925 per m2 per build (does not include land value).

Case study

The multi-award winning “Hope Rise” project is the first Modern Methods of Construction (MMC) development of its kind to be completed in the UK in 2020, overcoming various restrictions and nationwide lockdown due to COVID-19 . The project presented 11 affordable and low-carbon, modern design apartments which were installed as a permanent living space for young workers and vulnerable households. The environmentally friendly homes were erected on steel frame podium and built above a council-owned car park in Bristol. ZED PODS inhouse design team retained hundred percent of original parking provision for this project.

The super-insulated homes are fitted with low energy heating systems and renewable energy technologies (including rooftop solar panels) to complement a “fabric first” approach. Electric car charging upgrades were used to facilitate the shift away from the carbon-heavy transport use of the historic car park, while connections to local public transport and cycling/walking routes to local amenities help eliminate the need for private car ownership. The use of Cross Laminated Timber (CLT) enables the superstructure to be erected in days, helping to reduce carbon footprints during construction. This also offers the flexibility of adapting individual designs and internal layouts for the end-users. This project demonstrates that zero operational carbon affordable homes are possible to build within current financial models. Several local authorities and other stakeholders visited the scheme and were inspired of what can be achieved on a constrained site which otherwise would be difficult to build using traditional construction.

Hope Rise was built in 23.5 weeks as compared to 56 weeks build program for a similar housing scheme using traditional construction – which means early rental and financial benefits to council i.e. cost of temporary accommodation, early council tax etc.

A year long “Post-Occupancy Study” was undertaken by an independent body using remote sensors and energy tracking. The study found that 104% of the annual energy usage is generated onsite by the roof solar panels which validated the as design energy performance of the building, apart from improved wellbeing and employment rates of the residents.

Facts and Figures

£2,925

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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3D printed concrete beams designed to use less material /resources/3d-printed-concrete-beams-designed-to-use-less-material/ Mon, 12 Dec 2022 17:15:18 +0000 /?post_type=resource&p=30127 3D printed concrete beams for construction projects. 

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Problem Addressed

The built environment is directly responsible for 25% of UK emissions, lifting to 42% if you include surface transport. In order to reach Net Zero by 2050, the roadmap for the construction industry, from the , requires a 25% reduction in emissions by 2030, compared to 2020. Sustainable development in 21st century must include concrete solutions but there is no need to wait until 2030 for meaningful reductions in embodied carbon.

Solution Overview

minimass beams are a new type of 3D printed concrete beam, to be used as a prefabricated structural element in new-build construction.

They are designed to use less material – concrete and steel – to achieve the same performance requirements as typical concrete beams. minimass beams can reduce the quantity of concrete by up to 60% and the quantity of steel by up to 50% which also significantly reduces costs, with predictions of up to 50% reduced material costs.

The beams are designed to Eurocodes and can be a like-for-like replacement to traditional concrete, steel or glulam beams, with minimal change to the design of the rest of the structure. The beams use a geometry which responds to the applied loads and they have large web openings which allow services to pass through them.

This is a good solution for beams longer than 6m and an excellent solution for beams longer than 12m. For short beams, e.g. in residential construction, it is likely that steel or shallow concrete beams are more appropriate.

The beams can be used with precast concrete floors, composite metal deck and CLT.

The cost of the solution is split between material costs and manufacturing costs. The material costs are significantly reduced – by up to 50%. The manufacturing cost is driven by the 3D printing process and the location of the project. Crucially, the labour costs associated with 3D printing are low, therefore the overall cost for the beam is of the order of 25% less than a traditional concrete beam.

Case Study

There is no built case study available but the product has passed a range of laboratory tests and is now being marketed to projects in UK, Europe and Australia. Furthermore, a series of 6m long physical prototypes have been printed and assembled for destructive load testing. Working with a range of industry leaders, this testing process has been essential to validate minimass for the construction industry.

Facts and Figures

~25 %
<60 %
<50 %

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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3D printing optimised structures using less concrete /resources/3d-printing-optimised-structures-using-less-concrete/ Mon, 08 Aug 2022 09:46:06 +0000 /resources/revolutionizing-concrete-construction/ Optimising waste recycling into sustainable, 3D-printed concrete. 

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Problem Addressed

In the built environment, cement use is the cause of 8% of global CO2 emissions every year, according to the . Construction companies face the challenge of virgin material over-consumption, whilst industrial companies endure high storage costs and high risk environments from the generation of large quantities of waste.

Solution Overview

Hyperion Robotics combines large-scale, 3D printing with low-carbon concrete made of industrial waste materials such as mining tailings, ashes, slags and demolition waste. Their variety of sustainable infrastructure products include foundations, water tanks, trenches and buildings. They have developed a special construction material based mainly of mining tailings that uses zero cement. Accompanying this, their software enables optimized structural designs for 3D printing, resulting in minimal material usage. Clients can choose to use traditional cement-based concrete with the technology or low-carbon concrete made from local recycled materials.

The system has low power requirements at approximately 15kw/hr, though it may vary per project. Due to the decreased use of cement and virgin aggregates, embodied carbon is reduced, lead time is reduced by 50%, and the need for tailing storage facilities is lessened, limiting health and safety risks. Accompanying this, Hyperion Robotics also provides training, support and maintenance services.

Hyperion Robotics provides different options to allow customers to more easily adopt their technology – either an initial investment (£150k to £500k depending on the complexity of the systems) or through leasing it for a project / a certain period of time. Clients can expect an ROI in 12 months or less when Hyperion Robotics’ micro-factories are at full production, with 30% in financial savings due to the decreased use of cement and virgin aggregates. Their models and technology allow clients to easily scale up their production and execute projects that otherwise they would have not been able to deliver with traditional technology.

Case Study

Hyperion Robotics designed and produced 2 x 2 m water tanks for the mining industry made with almost 99% recycled mining tailings and zero cement.

Metso Outotec develops mineral processing plants for mining and industrial companies that allow the drying of mining tailings on a very large scale. Once the tailings are processed, Hyperion Robotics’ solution is used to complement Metso’s technology, allowing the use of a high percentage of this waste as a component in their concrete. The concrete has been used to produce sustainable infrastructure products for the mining company itself, but also for the surrounding communities. They are currently looking into building similar tanks with 10 x 10 m dimensions.

Facts and Figures

12 Months
50 %

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

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Reusable modular building system from waste plastic /resources/ogel-products-of-mass-construction/ Wed, 03 Aug 2022 13:33:16 +0000 /resources/ogel-products-of-mass-construction/ An easy-to-assemble, fully reusable modular building system that uses waste plastic as its raw materials.

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Problem Addressed

Changing weather conditions in the UK have made flood barriers a vital item for homes and buildings. For most of the year, they are not required, but when the time comes they need to be quickly assembled to combat and withstand rapidly rising water levels and to avoid devastating structural and internal damage. Without appropriate flood barriers, substandard housing will not be able to withstand the flooding force, and large quantities of plastic waste are generated through using temporary measures.

In addition to this soil and ecosystem degradation due to unsustainable development makes it increasingly difficult for lands to absorb the waters from heavy rains. A large part of the UK’s population are not aware that they are at risk of flooding.

Solution Overview

OGEL provides an easy-to-assemble, fully reusable modular building system that uses waste plastic as its raw materials.

In terms of Resource Use, OGEL is a ‘Full-stop product’. The aim of the product is to utilise recycled material rather than virgin material, with the final product having an especially long life cycle.

In terms of addressing the impacts of climate change, the system can work as a fast-build flood defence barrier as well as a disaster relief shelter due to it being lightweight, modular and quick to install and dismantle.

The socio-economic properties of the OGEL system are reflected in its use as semi-permanent homeless shelters, offices or any commercial building, removing the reliance on brick and cement in a cost-effective manner.

In terms of its properties and how it compares to other materials, the system has a low u-value of 0.17, meaning it has better thermal properties than brick. It packs to 1/5th of assembly size, is 88% lighter than traditional building materials and requires zero maintenance. OGEL panels are also coated with an intumescent coating which provides a high standard of fire resistance.

Although it is a standalone solution when it comes to certain projects, partnerships are always welcomed, for example wrapping OGEL buildings in a solar film to generate sustainable energy.

Use-cases:

  1. Temporary homeless shelter providing improved mental health and socio-economic benefits as a safe place to reside until more permanent solution has been met. Once the person is no longer in a dire situation, the building can be dismantled and moved elsewhere rather than building another one.
  2. Reusable flood defence, saving on the costs of further flooding events and allowing transportation of system to other effected areas. As a comparison, once sandbags have been contaminated it is recommended they are thrown away.
  3. WfH offices enable companies to improve their green messaging by offering plastic waste buildings to their employees. Employees also feel happier when their work environment preferences are considered.

Benefits of using OGEL:

  • Lower labour costs
  • Lower transportation costs and related emissions
  • Reusability and modularity resulting in lower waste disposal costs
  • Increase in home working resulting in lower commuting costs and emissions

Case Study

Whilst setting up a pilot plant for their solar film technology, Powerroll required a separate office space for their technicians. They required an internal office that catered for their needs whilst also being an environmentally friendly space that could enhance their green credentials. OGEL used its system to create purpose-built partitions that can be added to as staff requirements grow.

In order to adhere to their deadline for their official opening, they needed a rapid-assembly product that was flexible and soundproof, and which had access to power and broadband. OGEL completed a partition system in less than 5 days which is movable and can have courses added as Powerroll’s staff requirements grow.

Facts and Figures

0.17
88 %

This page presents data, evidence, and solutions that are provided by our partners and members and should therefore not be attributed to UKGBC. While we showcase these solutions for inspiration, to build consensus, and create momentum for climate action, UKGBC does not offer commercial endorsement of individual solutions. If you would like to quote something from this page, or more information, please contact our Communications team at media@ukgbc.org.

The post Reusable modular building system from waste plastic appeared first on UKGBC.

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