Off-Site Fabrication Project For Two Development Schemes In Central London

The project described below is a good example of one of our off-site construction projects and is representative of the typical challenges experienced by our customers and the support we are able to deliver.

About The Customer & Project

The project was delivered for a construction contractor working on two residential schemes in the heart of London, at Ashbridge Street and Cosway Street. The customer asked us to supply Wicona windows, doors, and curtain walls for properties on both sites. This was an off-site fabrication project, which meant that our windows were fabricated and delivered to a modular construction panel supplier based in Belgium. The goal was to install most of the windows off-site at our supplier’s location in Belgium, and then reimport them back to the UK as part of a modular construction panel.

Although there were some windows, doors, and curtain walling on the project that required on-site installation, opting for off-site fabrication would keep this to a minimum and help control costs for the customer.

Forever Homes

One of the specifications for this project was that the buildings needed to comply with the ‘Forever Homes’ standard. This means that the property must be fit to meet the standards of people who may be less able-bodied in the future. To accommodate this, several windows in each property had to be fitted with Teleflex winding gear to ensure easy operation.

The Challenge

There were a couple of challenges associated with this project that made it an interesting assignment for our team. Navigating the post-Brexit red tape while exporting the windows out of Belgium and importing them back was one of them – albeit one that our team knows how to deal with. We were able to expedite the process for the customer within a reasonable timeframe without incurring any unforeseen costs or delays.

Another challenge faced by the customer was getting the completed modular panels to pass the water test on site. Unfortunately, a slight flaw in the architectural plans meant that the mortar joints in the brickwork returned past the windows. As the mortar was porous, this allowed a large quantity of water to seep into the cavity. Our team worked with other contractors involved on-site to develop a detail that allowed the excess water to escape. An additive was applied to the brickwork to reduce the amount of water ingress. These two measures, combined, enabled the project to pass the water test.

Another challenge involved a late change of colour to the mastic – after around 30% of the project had already been sealed! As most of the windows had been assembled off-site, once the modular panels were installed on-site, we had very limited access. To replace the silicone, our team of installers had to abseil down the building and carry out their work suspended from the rooftop, in order to successfully complete the project.

Outcomes

The project was successfully delivered for the contractor, and by taking a forward planning and proactive approach to project management, we were able to anticipate and avoid any delays arising from the impacts of Brexit and Covid 19.

Unfortunately, Osbourne Construction went into administration shortly after completing those projects, but had the following to say regarding our involvement: “We appreciate your proactive approach and working with us to ensure that there is no compromise in quality!”

Find Out More

To find out more about this project and how our modular panel construction approach can benefit your project, please contact our team at Advanced Glass today by clicking here.