voestalpine Metsec SFS has been used in the construction of a major new city centre redevelopment project in Durham.

Situated along the banks of the River Wear in the centre of Durham City, Milburngate is a 450,000 square-feet mixed-use redevelopment of a site previously occupied by HM Passport Office and National Savings & Investments.

The development, which is due to open this year, will feature high quality restaurants, bars, a boutique cinema and contemporary offices together with a 92-bedroom Premier Inn hotel, 153 luxury built-to-rent apartments and a 600-space car park.

With views over the UNESCO World Heritage Sites of Durham city centre, Milburngate provides the city with a stunning leisure, business and residential destination as well as creating hundreds of new employment opportunities.

Milburngate is being delivered in joint venture by Durham-based property business. Arlington Real Estate and the Richardson family, who together have already successfully delivered a number of important regeneration projects across the region.

Main contractors, Tolent specified voestalpine Metsec’s lightweight, cold-rolled steel framing system, SFS for the external walls together with composite flooring on the hotel and three apartment buildings. The structures range from four to nine storeys in height and are constructed using a primary hot rolled steel frame.

The decision to opt for voestalpine Metsec SFS was taken following discussions between Tolent, the project’s architects and voestalpine Metsec’s technical sales team, with voestalpine Metsec undertaking design at the start of the project and guaranteeing to meet the project’s planned timescale for delivery. SFS Installation was undertaken by local specialists, James Paul Services Limited.

voestalpine Metsec’s design included individual spacing of studs to suit the layout for the Stofix Brickslip heavy rainscreen cladding. Special consideration also needed to be given to fire resistance; with the primary steel frame being protected by intumescent paint, a 52mm gap was maintained between SFS studs and the frame’s steel columns, whilst SFS sections that were fixed directly to the frame were finished with a similar intumescent surface treatment.

voestalpine Metsec Sales Manager, Andy Brayford comments, “Milburngate is a perfect illustration of the versatility of SFS in its ability to be used with a variety of primary frame materials, in this case hot rolled steel.

With our in-house team of experts taking care of system design, the SFS elements were manufactured to the precise requirements of the project, assuring efficiency in installation and enabling the project’s construction schedules to be met.”

voestalpine Metsec’s SFS steel framing system has been used extensively in the construction of two major landmark residential tower blocks in the heart of Birmingham.

The Bank development features two striking high-rise structures of 22 and 31 storeys, named Left Bank 1 and Left Bank 2, situated within easy reach of the Second City’s major commercial, business and leisure districts.

Designed by local architects, Glancy Nicholls for client, the Regal Property Group, the two buildings provide a mixture of luxury apartments, hotel and retail facilities. Extending to more than 100 metres, the taller of the two is Birmingham’s tallest residential building.

Wates Construction were appointed to build both tower blocks. The main structures were constructed from in-situ reinforced concrete columns, beams and floors, with voestalpine Metsec SFS being specified by the architects to provide infill to support the external cladding and glazing systems.

Performance, speed and economy were all instrumental factors in the decision to opt for voestalpine Metsec SFS:

From a performance perspective, the external walls of both buildings needed to be constructed from non-combustible materials. voestalpine Metsec’s ability to offer through-the-wall guarantees of SFS’s fire performance in use with a wide variety of insulation and cladding materials provided the assurance needed for this high-profile project.

Critical to the specification of SFS for this project was its ability to withstand the high wind loadings stipulated by the structural engineer’s calculations. Scale models of the buildings and their environment were used to undertake the fluid analysis which would determine potential wind loading on the structures’ façades.

As a result, 150mm SFS was specified, providing the additional strength required by the structural engineer’s calculations and greater flexibility during construction of the multi-storey buildings.

Speed and, hence, economy were achieved throughout the SFS and cladding installation process, which was undertaken by voestalpine Metsec-approved installers Isec Interior Systems.

SFS components were delivered to site on a just-in-time schedule from voestalpine Metsec’s production facilities at Oldbury, just a few miles from the site. These were then combined with insulation, cladding and glazing elements to fabricate complete panels and lifted into position using mast climbers. This allowed all four sides of each storey to be completed simultaneously, enabling follow-on trades to move in quickly and construction to progress smoothly.

Safety was assured throughout the installation process thanks to the fact that the majority of operations could be completed from the inside of the building.

voestalpine Metsec and SFS proved to be the ideal solution for both Bank 1 and Bank 2. We provided invaluable support at the design stage and the system installation was quick and trouble-free, allowing the project to be completed on schedule and the client to start realising returns on their investment.

In addition to giving Birmingham two stunning pieces of iconic modern architecture, The Bank provides almost 400 individual apartments, many with spectacular views across the city and all perfectly situated for local bars, restaurants and workplaces.

Imagery credit: Glancy Nicholls Architects

voestalpine Metsec’s lightweight steel framing system, SFS, is being used in the creation of a new £346m riverside residential development in the Barking and Dagenham area of London, which will eventually provide more than 900 new homes for the capital.

Fresh Wharf is being developed by Countryside, the UK’s leading mixed-tenure developer, in partnership with housing association Notting Hill Genesis on a 10-acre, former brownfield site situated along the banks of the River Roding, a tributary of the River Thames.

The site was previously used for commercial lettings before being acquired by Countryside. Demolition of old premises on the site started in early 2018 and Phase 1 of the two-phase construction project commenced later that year.

Working with architects and urban planners, Metropolitan Workshop, Countryside and Notting Hill Genesis have created a scheme which is designed to maximise the benefits of the river frontage and city views.

In addition to a mix of contemporary one to three-bedroom apartments together with three-bedroom townhouses, Fresh Wharf will feature a large, open park at its centre and three landscape-led public realm areas. Existing boat moorings will be reinstated and a selection of shops, cafes and restaurants will be incorporated in the development’s Northern Square, adding to the vibrancy of the area.

Phase 1 of the project sees the construction of 532 homes, accommodated in five apartment blocks of between five and fifteen storeys and ten three-storey townhouses.

Following the demolition works, Countryside needed to raise the level of the riverside site for protection against flooding. This was achieved by capping to achieve a finished floor level of 6.30m AOD.

After this, construction of the new properties commenced in earnest, with the apartment blocks and townhouses being constructed from concrete frames. It is here that Metsec’s lightweight steel framing system, SFS came into play, providing infill for the properties.

Almost 16,000m² of 100mm SFS was supplied as infill for the external brickwork facades of the apartments and townhouses. To assure compliance with NHBC moisture control requirements, SFS sections being used in areas such as the ground floor, balconies and roof terraces were manufactured from Z600 galvanised steel to provide added protection.

Installation was undertaken by specialist sub-contractor, Stanmore, with Metsec using Revit to create the construction level design for the framing system at the early stages of the project’s conceptualisation.

Garry Tarvet, Associate Technical Director, Partnerships East London, Countryside, comments, “Engaging with Metsec’s team at the very early stages of the project de-risked the design process for us. It ensured that the project could progress smoothly and avoided disruption of the design and construction processes, allowing us to meet our timetable.

“Metsec’s BIM and 3D modelling capabilities also allows them to integrate their designs with our own models, further streamlining the process and making the project much easier to manage from start to finish.”

Working with Metropolitan Workshop, Countryside has also taken a great deal of care to avoid Fresh Wharf being a standard frame and cladding development. External aesthetics have been assured by attention to detail in the selection and detailing of the brickwork, which includes sawtooth brick, basketweave details and multi-course soldiering to add variety, interest and quality to the final finish.

Collaboration delivers UK’s most connected bridge

The landmark Queensferry Crossing Bridge in Scotland is almost certainly one of the most efficient, high performance bridges ever built, incorporating a complex array of utilities and communications equipment.

Constructed alongside the iconic Forth Road Bridge, the Queensferry Crossing replaces that bridge as the main road route north from Edinburgh, carrying the M90 motorway across the Firth of Forth.

Officially opened in September 2017, the Queensferry Crossing took six years to complete and forms the centrepiece of a major upgrade to the cross-Forth transport corridor in the east of Scotland. It represents an investment of more than £1.3bn and is truly world class, setting a number of national and international records, including the longest three-tower, cable-stayed bridge in the world.

A partnership between cable management specialist, voestalpine Metsec plc, leading M&E fixings supplier in Scotland, MEF, and lead M&E contractor, SES Engineering Services, has been critical in ensuring the delivery of the systems that will support the 2.7km road bridge and assure its safe and efficient running for decades to come.

A major logistical project

The bridge deck is constructed from 122 composite steel/concrete sections. 250-tonne steel sections were manufactured in China and shipped to Rosyth docks, where they were then prefabricated to incorporate all of the services and road surfaces.

The cable management systems supplied by Metsec were prefabricated into 424 modules by SES and then installed into each of the finished 750-tonne road section decks before being delivered to site by barge along the River Forth and craned into position to span between the bridge towers.

All of the cable management products used had to be pre-approved by the bridge authority, Forth Crossing Bridge Constructors. With the support of Metsec’s technical team, thermal extension couplers were designed and incorporated into the project’s cable management systems to help compensate for the movements of the bridge caused by temperature fluctuations, wind and traffic.

A collaborative approach

SES, explains, “Whilst we have a lot of experience in major infrastructure developments, the Queensferry Crossing was a once-in-a-lifetime project that demanded a highly collaborative approach to ensure we could meet and match the exact requirements to deliver all of the component parts of the bridge on time and in budget.

“MEF are part of the SES-approved supply chain and they selected Metsec not only because they were the best from a commercial and quality point of view, but because they were able to supply the cable management systems we needed in special sizes, vitally important in terms of minimising waste and ensuring ease of fit. Particularly important was their willingness to adapt the units to minimise the number of joints required. Everything was spot-on in terms of enabling the teams to fabricate and install each unit on schedule.”

voestalpine Metsec plc supplied hot dip galvanised cable tray and cable ladders cut to special lengths, the trays to 3.5m and the ladders to 6.9m. The finished modules assembled by SES hold a complex array of water management and cabling needs from lighting and power to traffic management systems, security, fire alarms, radio communications, structural health monitoring and building monitoring, all designed to give optimal control over the management and performance of the bridge.

“It’s a highly complex installation that effectively acts as the ‘brains’ of the bridge, controlling everything from the timing of the lights to maintenance planning, with a focus on optimising efficiency and communications not just on the bridge itself but on how it communicates with the traffic management systems that feed into it.”

Reliability and quality

Alastair Fairweather, at MEF adds: “This was a fantastic project to work on and much of our involvement has been down to the support we have had from Metsec. We have worked with them for several years now and we knew that their involvement would be vital to us winning this contract. The sizes needed were not standard, but their UK-based manufacturing facilities gave us the option to offer a flexible, high-quality solution to SES that we knew Metsec could fulfil and deliver on time and in budget. In fact, flexibility was critical not just in securing the project but in meeting evolving requirements as the project progressed over the12 to 18 months we were there.

“We put a lot of faith in partnering with Metsec for what was one of the biggest projects we have ever worked on and it has really paid off. The reliability and quality of service from the Metsec team has been as important as the quality of the products they supplied. The 55 micron hot dipped galvanised steel tray and ladder systems used will need to endure exposure to the elements for up to two years before being completely sealed-in under the bridge, and the high quality of the Metsec product will contribute to keeping the whole life costs of the project down.”

Jon Hillier, Director at voestapline Metsec plc cable management division, adds, “The Queensferry Crossing project was something we were keen to be involved in from the start. We knew we had the capability to re-programme our mill to allow us to manufacture the specified lengths of ladder and tray in a way that would fit perfectly into the required modules. Working with MEF meant that we were also able to offer the just-in-time capabilities needed to support the tight pre-fabrication scheduling for each of the bridge’s deck sections. It is great to see the bridge finished and fully operational, knowing that our products are supporting the complex systems that will drive the functionality of this impressive infrastructure showpiece and help drive transport connectivity in the region for years to come.”

Oldbury-based cold roll-forming specialists, Metsec has supplied its market-leading Metframe pre-panelised construction system to create new student accommodation facilities on the site of the former BBC Pebble Mill studios near Birmingham city centre.

Designed by local architects, Glancy Nicholls, the £25 million project provides 357 high-specification, self-contained studios for students at local universities.

The building occupies 11,000 square metres with around 600 square metres dedicated to amenities which create a vibrant communal hub. These include dining facilities, study rooms, a gaming room, cinema and gym.

The structure comprises three tiered towers of four, five and six storeys, all constructed from Metframe and finished externally with stone and brick cladding panels.

Consulting engineers, BWB Consulting specified Metframe as the preferred solution for the loadbearing frame mainly due to its lightweight which facilitates significant savings in the construction of foundations. However, other key benefits of using Metframe also came to the fore at Pebble Mill in the areas of cost, efficiency and quality.

Metframe panels were fabricated off-site by Metsec-approved installer, Atkin Trade Specialists. The lightweight steel panels were then delivered to site ready for immediate installation. Atkin Group Director, Thomas Atkin comments, “The Pebble Mill project is a perfect demonstration of Metframe’s strengths. With wall panels manufactured off-site, other construction processes, such as foundations and services, are free to proceed unhindered until the project is ready for the panels.

“Panels are then delivered according to the project’s schedule and erected as soon as they arrive on site.

“The main structure takes shape quickly and efficiently, with follow-on trades able to start their work very soon after Metframe has been installed.”

From a contractor/client perspective, the structure at Pebble Mill was completed in around 18 weeks, allowing contractors, Morgan Sindall to deliver the finished project ahead of schedule and clients, Vita Student to start letting the accommodation earlier than anticipated.

Additionally, Metframe enabled the structure to be built to precise tolerances, as Steve Ginger, Director of Framing at Metsec, explains, “Quality on this project was particularly important. Each cell needed to be true to ensure that follow-on fitting of windows, reveals, services, external cladding panels and other items could proceed smoothly.

“Using Metframe proved to be advantageous as it allowed Atkin Trade Specialists to meet these demands and the contractor to deliver a high-quality finished building, both inside and out.”

In all, Metsec supplied more than 17,000 cold-rolled elements for the project, together with the requisite bolts and fixings necessary for the fabrication and installation of the Metframe panels.

Metsec’s CE marked purlins and side rails used to upgrade Execution Class 4 Ashton Gate Stadium project

Specialist structural steel manufacturer, voestalpine Metsec plc, supported the £45m upgrade of Ashton Gate Stadium, which is home to Bristol City Football Club and Bristol Rugby Club, to transform it into a state-of-the-art stadium that can hold 27,000 people. Metsec supplied its specialised, rolled to order, steel purlins and side rails that have been CE marked under the Construction Products Regulation in order to meet the requirements of this Execution Class 4 development.

The transformation project, was separated into three phases so that work can be carried out on the Wedlock, Dolman and Williams stands. Phase one saw the 86-year-old Wedlock Stand demolished and now includes new conference facilities, administration offices and a cafe. The second phase was the redevelopment of the Dolman Stand to showcase the stadium’s new sports bar, as well as one of the UK’s largest sports screens and a Heineken lounge that seats 250 people. The final phase was a complete reconstruction of the Williams Stand, which was replaced with a two-tier stand to hold 11,000.

Having already supplied purlins and side rails to phases one and two of the project, Metsec was contracted by the design team at J&D Pierce to work on phase three. The purlins and side rails implemented throughout each phase were designed to provide optimal levels of structural performance in roof, wall and floor constructions.

The Ashton Gate Stadium project is Execution Class 4, which specifies the highest level of quality control required within the fabrication process. Metsec’s processes are certified up to this maximum of Execution Class 4, giving the industry absolute assurance that its construction products meet the required standards for any project, whether it’s a warehouse or a football stadium. By using products that are of this standard, Ashton Gate Stadium is confidently able to provide a venue that is safe and aligned to the European construction standard.

Andy Caldwell, Estimating Manager at J&D Pierce, commented: “For such a large scale project that is going to welcome thousands of sporting fans, it is essential that the structure of the regenerated stadium is of the highest standard. This is why we wanted Metsec on board, as we know that it is leading the way in terms of lightweight galvanised steel building systems with all its construction products being CE marked.”

David Brown, Sales Director for Metsec’s Purlin Division, commented: “We understand that on every large scale construction project that is going to be hosting a large amount of people at any one time, the structure that is being implemented needs to have longevity for the performance of the stadium and also for safety of personnel. Whilst the Ashton Gate Stadium project was underway, the stadium has remained open meaning that work being carried out has had to be managed in a way that does not affect the overall operation of the site.”

All Metsec products for use in construction are CE marked under the Construction Products Regulation, with its processes certified up to EXC4, which is the highest accreditation available. This means Metsec can deliver the required standards, regardless of the scale or bespoke nature of a project.

Take a look at Metsec’s Purlins and Side Rails Systems

Following a recent visit by monitors from the Considerate Constructors Scheme, voestalpine Metsec has been awarded a rating of ‘excellent’ across all areas of assessment.

The Considerate Constructors Scheme is a non-profit-making, independent organisation established by the construction industry to improve its image. Companies and organisations voluntarily register with the scheme and agree to abide by its Code of Considerate Practice, which is designed to encourage best practice beyond statutory requirements.

The scheme is concerned with any area of construction activity, both on and off sites, which may have an impact on the industry’s image, mainly involving the general public, the workforce and the environment.

Members of the scheme are subject to regular visits by scheme monitors who undertake assessments in five key areas; Care about Appearance, Respect the Community, Protect the Environment, Secure everyone’s Safety and Value their Workforce.

The monitor’s report for voestalpine Metsec’s Oldbury-based design and manufacturing facilities recognised the company’s commitment to the scheme throughout all areas of operations.

Of particular note were the number of external accreditations and certifications that the company has been awarded, staff training and development and environmental responsibility, with the majority of suppliers being within a 10-mile radius and zero waste going to landfill.

Commenting on the achievement, Sales Director for Framing at voestalpine Metsec, states, “We recognise that maintaining our position as the industry’s leading designer and manufacturer of cold-rolled steel products is not just about the quality and performance of the products themselves; it requires a skilled and motivated workforce and a focussed approach to all areas of our operations. The Considerate Constructors Scheme embodies these values and we are thrilled to be recognised for our workplace practices and standards.

“The ‘excellent’ rating demonstrates the efforts made by all our employees in creating an environment and culture that fosters success. It is further proof of our commitment to excellence and will spur us on as we strive for continued improvement.”

Discover more about voestalpine Metsec today and explore our quality control measures with our Quality, Health, Safety and Environmental Policy Statement.

The £215 million waterfront development at Millbay in Plymouth is transforming what was once an unused docklands area into a vibrant waterside community, by bringing together some 140,000 square metres of housing, workspace, retail and leisure accommodation.

Steeped in maritime history, the heritage of the wider Millbay area can be traced back to the 12^th Century when tidal mills were built in this natural water inlet. Centuries later, the Corporation of Plymouth sold the lease to Francis Drake and during the English Civil War, the harbour became a vital supply route for the city, which had sided with the Parliamentarians, as it was the only one in Plymouth that was out of reach of Royalist artillery.

In the 18^th Century, the harbour started to take shape, with jetties, work yards and other facilities constructed.

Development of the area gained pace in the 19^th Century, with Isambard Kingdom Brunel designing new docks as well as introducing a railway and customs facilities. Thus, Millbay’s potential was realised, becoming an important commercial dock for freight and passenger traffic.

As the area fell into disuse in the 20^th Century, it was identified as a strategic priority for regeneration in Plymouth thanks to its waterside location, proximity to the city centre and the positive socio-economic impact on the locality.

Working in partnership with Plymouth City Council, The English Cities Fund – a joint venture between Muse Developments, Legal & General and Homes England – embarked on a seven-phase regeneration programme which will, ultimately, deliver up to 600 new homes, together with offices, retail and leisure spaces, 171-berth marina, hotel, 1,000-place creative arts school and multi-storey car park.

Forming an integral part of this redevelopment is Quadrant Wharf, a £23 million quayside development of split-level houses and apartments which will provide 137 new homes.

Designed by architects, Ferguson Mann, the apartment blocks at Quadrant Wharf include two, five and six-storey structures forming Aqua House and Lye House, while a selection of cleverly designed split-level homes make up Canola Row, providing light and airy living areas with balconies and roof terraces.

The apartments offer one, two and three-bedroomed homes, including exclusive two and three-bedroomed penthouses.

With external facades finished in a combination of render, shiplap cementitious board, standing seam metal and stone, the apartments present a striking frontage looking over the Quadrant Quay marina.

The buildings were originally conceived as reinforced concrete construction when the designs were passed to main contractors, Galliford Try. However, as the company’s Pre-construction Manager on the project, Diarmad Perry, explains, Metframe offered a more deliverable solution; “Previous experience with Metframe had proved the system to be economical and fast to use, and we knew that we could trust Metsec to value engineer a solution, which would translate the architect’s designs into a quality, high-performance and robust structure.

“The pre-panelised, light-gauge steel system proved highly adaptable in enabling us to achieve the architect’s design vision and, just as importantly, delivered buildings which would meet all of the performance criteria. In addition to fire, acoustic and thermal performance, these included consideration of the fact that the apartments were in a severe coastal environment and would need to meet NHBC and building control requirements.”

Metframe components were assembled into lightweight panels by BR Hodgson Framing Limited at their specialist fabrication facilities at Upton upon Severn, before being delivered to site and erected by the company’s installation team. The lightweight, loadbearing steel frame was installed above a ground floor podium deck.

Andy Petrie, commercial director at BR Hodgson, comments, “The Metframe system allows us to manufacture structural wall panels, complete with external boarding, and internal partition walls off site. The panels are inspected to assure quality before being delivered to site ready for immediate installation by our team.

“With working time on site limited to nine to five on weekdays and nine to twelve on Saturdays, construction time was at a premium and Metframe proved more than capable in allowing the project to proceed smoothly and efficiently. We cast the in-situ reinforced concrete floors and roof terraces on metal decking as installation progressed, and the structure quickly took shape; the frame was completed in a little over six months, enabling follow-on trades to complete external and roof finishes as well as the internal fit-out.”

Metsec Framing Managing Director, Stephen Ginger concludes, “The apartments at Quadrant Wharf perfectly demonstrate the many advantages of using Metframe. Our design team was not only able to deliver the type of value engineered solution for which Metsec is renowned, but also to incorporate the project’s special requirements, which included a variety of large and small balconies.”

Visit our Metframe page to find out more