Housebuilders are facing a paradox. The UK government has urged them to ‘Get on and Build’, while British clay brick factory closures could, effectively, put a ‘block’ on building. However, there is a readily available alternative manufactured on UK soil – concrete facing bricks. So here, Tom Greening, Strategic Account Manager for Regional Housebuilders at Tobermore, explains what housebuilders should consider when specifying concrete facing bricks for their developments.  

Recent clay brick factory closures mean the UK market has lost between 300 million and 400 million bricks from its manufacturing capacity. Those that are left are under pressure from capacity constraints and high energy prices. So, as the government wants home building to accelerate, developers could face ever-longer lead times and rising costs as clay bricks will need to be imported from the continent to meet demand. These increased lead times could significantly impact the build programmes for new home developments. 

The problem is that delays won’t just eat into developers’ profits; they could result in hefty fines. To drive the delivery of its targeted 1.5 million homes within the next five years, the UK government has announced new powers for local councils. Delivery timeframes will become a condition of planning permission, and housebuilders will be compelled to submit annual reports showing build progress. A ‘Delayed Homes Penalty’ worth thousands for each unbuilt home will be introduced to penalise developers who consistently fail to build on consented sites or use planning to trade land speculatively.  

The good news is that housebuilders can mitigate the risk of delays and safeguard material supply and prices simply by switching their specifications to concrete facing bricks.  

Concrete facing bricks offer design appeal 

New developments must have kerb appeal to attract home buyers and may need to tie into the local plan by matching the style and colour of bricks used in the neighbourhood. So, aesthetics will always be a key specification factor for specifiers and developers.  

Concrete bricks are manufactured from cement, aggregates and iron-oxide pigments. They come in a range of colours from warm reds and vibrant buffs to contemporary slate greys, with smooth or tumbled finishes. This gives specifiers and developers a great variety to realise their design. They can choose concrete facing bricks that are virtually indistinguishable from traditional clay bricks and can opt to create a traditional finish, contemporary look or even cutting-edge designs 

Concrete facing bricks offer excellent colour retention thanks to high-quality iron oxide pigments, ensuring they preserve their vibrant hues over time. Most reputable manufacturers vapour cure their bricks for a minimum of 12 hours during the manufacturing process to help reduce efflorescence.  

Installation will support delivery programmes 

When specifying a building material that is new to them, developers will need reassurance that it can be installed quickly and easily so that build schedules, quality standards and on-site work processes are met. Although there are small differences between how clay and concrete bricks are laid, most bricklayers are proficient at both. Reputable manufacturers also provide step-by-step installation guides and training, brick sample panels and on-site technical support to ensure a quick and smooth transition for those new to concrete facing bricks. 

In terms of the actual installation, while concrete bricks are slightly heavier than traditional clay, the difference is minimal. In fact, their consistent sizing has been found to make it easier for bricklayers to achieve straight perpend joints, which improves laying speed. As a result, tests have shown that concrete facing bricks can be laid as efficiently as clay, achieving lifts of 1.5 metres or 20 courses per day (BS 8000-3). 

Cut levels of embodied carbon 

Sustainability is an increasingly important factor in specifying construction materials, with the 2024 pilot version of the UK Net Zero Carbon Buildings Standard setting ambitious annual targets for the carbon footprint of new homes. To meet these, developers must significantly reduce the levels of embodied carbon from construction materials. 

Some materials have higher levels of embodied carbon than others due to their manufacturing methods. For example, the average levels of embodied carbon in clay bricks are 453.19kg CO2 per 1000 bricks. This is 56% higher than the levels of CO2 in Tobermore’s Kingston Facing Bricks.  

To ascertain accurate sustainability credentials, always ask your manufacturer for the Environmental Product Declaration (EPD), which will include the specific levels of embodied carbon for that product. 

Ensuring a reliable pipeline 

To ensure that build programmes can be delivered on time and within budget, developers will need guarantees regarding the product pipeline. Again, concrete facing bricks have an advantage over clay here. Many UK manufacturers hold their core ranges in stock, and even if order volumes exceed readily available stock, concrete facing bricks can be produced at speed, so they can usually be delivered in line with site build schedules.    

In terms of price, concrete facing bricks are typically more cost-effective so, as a guide, they will cost around 10% less than clay, regardless of manufacturer. 

With the government applying pressure on housebuilders to build new homes at pace under the risk of hefty penalties if they fail to deliver, it makes sense for housebuilders to secure their supply chain now. Switching their specifications from clay bricks to concrete facing bricks makes good commercial sense. Not only are they cost-effective and readily available, but they also offer versatility of design, are easy to install and lower in embodied carbon. 

For more information on Tobermore click here. 

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Chris Meek, Specification Manager at Saint-Gobain Weber, explains which external finishes can help address the issues presented in different environments, as well as sharing some of his tips for working in the winter.

According to the Met Office, winters in the UK will be up to 30% wetter by 2070. While this seems a long time away, the homes being built now should long outlive this date and in order to do this, housebuilders and developers need to consider how the products they are specifying for the exterior of the property will help this.

External finishes
Render is one of the most flexible options for exteriors and allows housebuilders to achieve an attractive and durable finish. Render can be used to create a range of finishes including scraped, roughcast or dry dash as well as features such as ashlars and quoins.

For properties in areas of high exposure, dry dash – also known as pebble dash or harling – is often a popular choice.

A great example of dry dash in use is on a 168-home Barratt Homes development near Inverness. As one of the northernmost points of the British Isles, Inverness can be a place of weather extremes.

While dash is commonly used to give an extra layer of protection, traditional multi-coat dashing products typically take up to seven days to cure. This slows the housebuilding process and increases the cost.

After researching properties in the local area, Kevin Urquhart, construction director for Barratt Homes North, was impressed with the ‘standout’ finish of some new homes. Further investigation revealed they had been finished with weberend one coat dash; a one coat render that can receive a dry dash finish without the need to apply a second pass.

After verifying the claims of faster application and versatility with applicators who had first-hand experience of using the product, Kevin decided to specify it at Culloden West to reduce the building programme by approximately two days per plot.

Another benefit of using weberend one coat dash is that because it only requires one coat of render, developers can optimise any good weather days to reduce scaffold times and complete builds quicker.

Application depths
Depth of application is also important for longevity when up against the elements. Thickness requirements are impacted by location, orientation and exposure to wind and rain. The recommended thickness for sheltered to moderate exposure is 15mm and in more severe environments, such as coastal properties, this increases to 20mm.

The type of cavity wall insulation also has an impact. For a full fill cavity, the render must be thicker to provide two lines of defence against water infiltration.

Working in damp conditions
Working in wet weather can affect the texture and consistency of a render finish. If it is excessively wet, it can also degrade the bond and adhesion which could lead to serious problems.

Do not apply render during rainfall or when it is anticipated during the initial set. Render is susceptible to damage within the first 24 hours of application and must be protected in adverse weather conditions.

Winter working
When it comes to working in the winter, do not apply products in frosty conditions and always look at the minimum application temperature on the product packaging.

It is recommended that you check the temperature of the substrate before commencing work. Even if it’s 5°C outside when you are applying, the temperature could have been sub-zero a few hours previous and so the substrate is likely to still be frozen.

If the substrate is damp and the moisture freezes, the render will not adhere correctly. Protecting the substrate can help save days on site waiting for the weather to warm up to dry out the surface. Tenting the scaffolding or the use of mesh and cloths will help with this.

Rendering in cold weather can create lime bloom and while this doesn’t diminish the integrity or strength of the product, it can affect the aesthetics so protect your new finish using suitable materials.

Topcoats and decorative finishes can also be affected as cold conditions make drying slow as they rely on the evaporation of moisture within the product to set. Always follow the product’s guidance on this.

Beating the chill
With some products, an accelerator can be used at mixing stage which will speed up the initial set time. A product such as weber accelerateur monocouche can be used to reduce the time of scrape for through-coloured monocouche renders when working in temperatures as low as 5°C in the winter. If added at the correct dosage, it will achieve 20°C scrape time when working at 5°C.

My final tip for working in the cold is to ensure materials are protected from the elements or that they are moved to a location that is heated or warmed prior to mixing and application so that contractors can get on site and deliver a high-quality finish, first time.

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As the current popularity for Architectural Masonry shows no signs of slowing down, Sean Welch, Area Sales Manager at Forticrete, explores why these cost-effective building materials are supporting developers in achieving a new generation of residential properties that offer real kerb appeal, without compromising on durability or performance. 

Whilst concrete masonry blocks have been around for decades, they have traditionally been specified more for commercial projects based on their superior strength, minimal drying shrinkage and low maintenance properties. However, in more recent years, concrete masonry blocks have been rising in popularity with developers, facilitating a real step-change within the industry in regards to the building fabric of residential developments, particularly throughout London and the surrounding areas of South England.

Offering housebuilders the opportunity to replicate the high quality appearance of natural stone, combined with the associated performance and resilience benefits of commercial developments, concrete masonry blocks are an economical and effective construction method that supports unlimited design freedom and delivers uncompromising quality. 

Providing a comprehensive range of finishes, profiles and shades, concrete masonry blocks are enabling developers to construct a new generation of residential properties that create outstanding aesthetics, without causing additional strain on budgets or resources. 

These diverse finishes include rugged, tactile textures such as Splitface, Shot-blasted and Fairface, which emulate the natural appearance of stone to deliver an affordable alternative that provides a high quality and robust surface finish for the entire lifespan of the property. It also enables new build developments to seamlessly blend into their surrounding environments as soon as they are constructed. 

Available in an assortment of colours, from Bathstone, Straw and Terracotta, to Damson, Pewter and Flint, the exterior character of each property can be further customised to create a visually striking home that captures the immediate attention of prospective buyers. 

For more contemporary developments, smooth concrete masonry blocks that feature delicate, tactile finishes are a popular choice for creating sleek exteriors that combine rich blends of selected natural aggregates. This includes Polished Florentine® and Trentino finishes, which are also available in a suite of colour variations.

The use of concrete masonry blocks can also produce a unified aesthetic across the entire exterior of a property as the blocks have a higher resistance to moisture due to their low dry shrinkage, which enables them to be installed across the whole building fabric, including below DPC level. 

The low dry shrinkage properties also helps to minimise the frequency of movement joints installed throughout the masonry wall, with joints required every nine metres externally and every 12.2 metres internally, in ideal conditions. This means the overall design of the exterior isn’t restricted to a certain visual design or specific use of multiple building products to ensure the suitability and water tightness of the house.

The addition of complementary concrete masonry solutions, including arches, lintels, radius blocks and square or circular column surrounds, can also support developers in customising each house, whilst still achieving a cohesive identify across the whole development. 

The combination of functionality, performance and aesthetics is further bolstered through the proportion of the blocks, which provide increased dimensional stability. This significantly aids ease of installation when on site, whilst simultaneously reducing the quantities of mortar required.

Concrete masonry blocks also offer impressive environmental credentials, supporting housebuilders in specifying products that are recognised within the Code for Sustainable Homes and the Green Guide to Specification as an A or A+ rating. 

Forticrete is aiding housebuilders in taking their commitment to sustainability one step further through its comprehensive range of concrete masonry products that feature recycled content of up to 20%. This includes the revolutionary Hi-Light® block, which has been designed to provide all of the benefits associated with dense masonry, yet is up to 25% lighter than an equivalent solid masonry unit. This is due to its unique construction, which features a cellular underside, combined with a solid top surface that creates a full bed for mortar.

As developers across the UK continue to set the pace for a new standard of housing that revolutionises the visual and performance capabilities of the building fabric, the specification of concrete masonry blocks can support professionals in achieving the most effective, economical and ecological building exteriors possible. 

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Adrian Pargeter, Head of Technical and Product Development at Kingspan Insulation, reveals how tapered roof insulation can ensure effective drainage while keeping properties warm.

Keeping out the elements is the most fundamental purpose of any dwelling. Here in the UK that often means dealing with a good deal of rain and cold temperatures, particularly at this time of year. For buildings with flat roofs, it is crucial to ensure that the structure is well insulated and has suitable drainage provision through a designed fall. Tapered roof insulation can meet these requirements in a single solution, and recently introduced systems now incorporate Phenolic packer boards, allowing the overall build-up depth to be kept to a minimum without compromising performance.

The name ‘flat roof’ is something of a misnomer as these structures should always have some level of pitch to allow effective rainwater runoff. BS 6229: 2003 defines flat roofs as “having a pitch less than 10^o to the horizontal”, although some may extend this to pitches of up to 15^o.

The standard recommends that flat roofs should have a design fall of 1:40 and a minimum “as-built” fall of 1:80. Failure to provide a suitable fall will often result in water ponding. If untreated, this can lead to a number of further issues including alkaline formation and mould growth. The additional roof loading can cause further deflection, aggravating the issue and potentially reducing the design life of the roof.

Roof insulation

Properly insulating the roof is also an important consideration, both to achieve compliance with the relevant Building Regulations or Standards and to help to maintain a comfortable internal environment for homeowners. Kingspan Insulation recommends specifiers aim to achieve a U-value of 0.11 W/m^2.K (in England & Wales) and 0.10 W/m^2.K (In Scotland) for new domestic properties and 0.14 W/m^2.K for new non-domestic buildings.

Typically, this can either be achieved with a warm roof construction, where the insulation layer is installed above the deck, or a cold roof construction, where insulation is installed between and below the roof rafters with a minimum air gap of 50mm between the insulation and the deck.

Recently, a trend has emerged where installers fit a hybrid solution with a thin layer of insulation above the deck and the rest below. Whilst in principle this may seem like a sensible way to reduce the above-deck construction depth whilst eliminating the need for a below deck ventilation gap, it can lead to significant long-term issues.

In a warm roof, condensation is prevented by keeping the deck at a warm temperature, therefore there is no cold surface for the condensation to form on. In a cold roof, condensation is prevented as the ventilation current takes away the moisture vapour before it can form as condensation.

With the hybrid solution, however, the above-deck insulation layer often offers insufficient performance to keep the deck warm and, as the ventilation void is absent, there is no way to remove the moisture before it forms condensation. This construction should only be considered if a full condensation risk analysis is carried out and even then, it will rely on an almost perfect level of workmanship.

Tapered insulation systems can provide a better alternative, delivering excellent drainage and thermal performance in a single solution.

All-in-One

Tapered systems typically comprise sloped tapered boards, hip and valley boards and flat packer boards. They can be installed above concrete and metal decks either with standard waterproofing or as part of a green roof system.

The systems offer a number of practical benefits for contractors. Tapered insulation systems can be fitted with a dry installation process, meaning no time is lost waiting for the surface to dry. In many cases, these systems can be fitted above the existing roof surface, further streamlining project time scales. They can also weigh as little as 1.5% that of a screed to fall system – removing structural loading concerns.

Tapered systems are typically manufactured from rigid insulation such as EPS (expanded polystyrene), XPS (extruded polystyrene) or Polyisocyanurate (PIR). For enhanced thermal performance, systems are now available which combine PIR sloped, hip and valley boards with Phenolic insulation packer boards with thermal conductivities as low as 0.018 W/m·K. The packer board’s enhanced level of thermal performance can allow desired U-values to be met with thickness savings of 20 – 40 mm, depending on the individual scheme and build-up, when compared with a full PIR system.

Some suppliers also provide a tapered roofing design service to support installers. The system boards are provided with a clear layout tailored to the specific design of the roof. This allows a simple installation and ensures the desired level of rainwater run-off and insulation performance to be achieved with a minimal construction depth. Some also include a full condensation risk analysis as part of this process.

Flat roofs can provide distinctive style to conventional detached and semi-detached properties as well as a more easily maintainable roof space for multi-unit housing. Tapered roof insulation systems incorporating phenolic insulation can provide a quick, thin and lightweight solution for these roofs.

The post Roofing | A guide to Tapered Roof Insulation appeared first on PHPD Online.

Creating adequate parking spaces is a challenge for all housebuilders, but what if the solution was right underneath our feet! PHPD finds out more about one underground parking option, Cardok.

Parking – it is one of those issues, like the roads and the weather, which almost all of us bemoan at least once a day. For housebuilders it often causes even more of a headache. Usually a planning stipulation for new homes, finding the space to create parking spaces, especially in town or city centres, can be a significant challenge. Often the number of units or the overall floorspace of a property ends up being sacrificed to make room for the parking spaces.

One company with a solution designed to alleviate this issue is Cardok. It allows two cars to be parked, where previously there was only space for one. This is achieved by going underground. The Cardok system features a hydraulic lift that brings one car (or more) underground while leaving space above for another vehicle. Not only a clever idea, the solution could also bring a ‘wow’ factor to a new property.

Nick Sandy, chief executive of underground parking solutions company Cardok UK explained how the company’s team of planning consultants have been working on one project in London: “We are currently installing a Cardok inside a former coach house in central London where the client has built an eight- bedroom property.

“The property doesn’t have a driveway and the client could only park one car in his existing garage. The Cardok will allow him to double his parking space. We help the architects by supplying CAD drawings of the Cardok and have a team of expert planning consultants who can assist with any planning application.”

A luxury solution?
But is this system better suited to ‘high-end’ luxury properties or can it be a solution for more modest new builds with parking problems? Nick Sandy believes it is suitable for all types of situations.

He tells us, “we are developing new affordable parking solutions that are more cost-effective in relation to the land cost. With a modest starting price of £35,000 the latest Cardok model is suitable for all types of property and given the high cost of land, the Cardok can in many cases pay for itself. Even our most expensive two-car model at around £55,000, allows cars to be lowered several meters to a basement car park and is proving very popular, especially in London where parking space is a major issue.”

Security is a key issue when it comes to parking and the company believes that the Cardok is ‘more secure than a garage’. Nick Sandy explains: “The Cardok is typically installed in a concrete bunker and access is only possible via the owner’s control system. We offer fingerprint and retina access systems as options, [plus] being out of sight means that thieves and vandals don’t know there is a vehicle below ground.”

Installation
Cardok requires specialist installation. Prior to the installation the housebuilder would need to install the underground space (the company supplies the specification and dimensions of the concrete pit that is required) and the required electrical supply – typically three-phase, although the Cardok can be run from both single and three-phase. Once this is completed the company’s own team will take around two days to install and commission it. A team of structural engineers are available as required.

The maintenance schedule requires only one visit per annum to check the hydraulic system and for a general safety check. In addition the company offers a next-day site attendance service if necessary.

Nick explains that the Swiss design engineering is of a particularly high standard, “with triple redundancy built into the lift system and various fail safes are included.” The company can also supply a small back-up generator so that owners can always gain access to their cars, even if there’s a power cut.

Rain and surface water
With a great deal of wet weather in the UK Cardok has been designed to be watertight. Nick explains: “It has a U-shaped guttering system – made from 8mm galvanised steel – that forms the top edge of the Cardok pit. When the upper deck lowers into its resting place the deck and the gutter interlock thereby preventing any leakage into the underground garage.

“Any surface water will drain into the guttering system. We also install a sump pump in the basement to deal with any run-off water or snow from the car. This pumps any water to the property’s drainage system.”

Finishing touches
The company promises that each platform can be custom fitted with just about any finish the client requires, from paving stones and cobbles to resin, tarmac and timber. Typically the finish will be paving stones to match the surroundings, but it has had grass and plants – even carpet – on the upper surface as well.

Nick hopes that the system, “will help begin a parking revolution, especially in historic cities like Bath” where the company is based. Other options available from the company include turntables for manoeuvring vehicles in tight spaces.

Nick explains that in Antibes, in the South of France, one client has installed a Cardok to access his five-space garage under a newbuild villa and incorporated a 5m turntable to facilitate easier access. The company calculates that the installation of the Cardok has saved about 2,500 square feet that can now be used for living space.

www.cardok.com

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