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The Eco-house A practical design and build project for construction UTCs July 2014
1.0 Executive
summary
This report illustrates how a hands-on design
and construction project can be integrated
into the curriculum at a construction UTC.
The construction of the eco-house is the
culmination of two 6-week-long projects in
which students will take on the role of a small
residential design & build contractor looking
to develop a new eco-house. (See the
previous report in this series titled 10 project
themes for practical implementation of the
construction curriculum at UTCs to
see how the eco-house project fits in
with the other eight project themes for
construction UTCs).
They will have to construct a show-home
demonstrating the technologies they can
use. Teams will compete to persuade
a committee of investors to fund the
development of their product.
The projects will be managed and facilitated
by the UTC, but will require significant
input from employers to make the projects
realistic, valuable and safe. Employers
will be asked to provide focussed expert
guidance during the design and construction
planning stages, acting as mentors and
clients for the project teams.
Significant support from employers
will additionally be needed during the
construction project, where they will need
to supply skilled personnel to support the
students in completing the construction.
The Eco-house A practical design and build project for construction UTCs July 2014
2.0 Introduction
The activities the students will be under
taking to design and construct their ecohouse will teach students about the
characteristics of a range of different
materials and construction types used
to enclose the spaces we live and work
in. While learning this, the students will
gain an improved understanding of the
structural and environmental design of
buildings, will have to do detailed planning
of the construction project and will gain
hands-on experience of the construction
of each of these materials.
Additionally students will examine the
social and economic drivers for housing
construction, and will experience first-hand
the regulatory and planning constraints that
must be considered when designing and
building housing.
Students will be presented with a palette of
different construction materials with which
they can complete the eco-house, with a
brief to optimise the energy performance
of the building without compromising the
internal environment for its occupants. They
will have to achieve planning permission
for their eco-house before they can proceed
with construction, and will need to balance a
number of different, sometimes conflicting,
requirements in order to be ready to
construct their house.
3.0 Responsibilities
The eco-house they build will be a one- or
two-storey structure. The ground floor has
a fully completed structural system, requiring
only that appropriate wall systems are used.
The optional first floor however will have only
part of the structure completed, and students
will have to investigate the most appropriate
ways to build a stable light-weight structure,
at height, using the available materials.
Students will have to consider weight and
buildability in their planning, and will be
encouraged to understand braced and
framed structural solutions.
An eco-house has been chosen as it offers a
good opportunity to examine the economic,
environmental and social merits of different
materials in domestic construction, and
addresses what is increasingly a key theme
and consideration in the built environment.
It is an opportunity to really challenge
students to think and learn about
sustainability in construction and the
challenges and opportunities it presents.
The Eco-house A practical design and build project for construction UTCs July 2014
The Eco-house A practical design and build project for construction UTCs July 2014
Design
Students will gain experience of the design
of buildings. Although the steel primary
structure is already designed in advance, the
student teams will have to design the infill
and possibly a light-weight first floor structure
and roof and any temporary works needed
for the construction. They will have a number
of constraints to both guide and limit their
design tasks, which will include the planning
and regulatory conditions theyve already
examined and a newly presented client brief.
The briefs primary requirement will be to
design and build a small energy efficient
show-home using a range of technologies,
and will include a number of cost and
material constraints. They will have the
opportunity to examine the brief and
discuss it with the client (a role fulfilled by
the employers). Students will be encouraged
to challenge the brief and enter into a
constructive dialogue with the client to
address conflicting drivers and difficulties
they may identify. Students will learn how
constraints in the real world can provide
opportunities and difficulties for the
design process.
They will have to follow an iterative
design process, which will include
making a planning submission in order to
obtain planning permission from a planning
committee and obtaining final design sign-off
from the client, before going on to produce
drawings and simple specification from which
their designs can be built. Students will have
to consider the buildability and safety of their
designs. The first project will conclude with
the issuing of construction information. (3.3,
3.4, 3.5, 3.6, 3.8, 3.17)
Construction planning
Students will have to plan the entire
construction task, and will have to actually
carry out their plans. This will provide a
direct link between the role of the designer
and the role of the contractor. Students will
need significant input and support from the
employers in guiding them through
the planning process.
The planning will include the construction
timetable, and students will have to know in
advance what materials they will need and
when. They will have to deal with any errors
or oversights in their planning, and with
subsequent delays or penalties, during the
actual construction. This will be an extremely
valuable experience and will drive home the
importance of understanding your project
fully in advance. (3.3, 3.5, 3.7, 3.10, 3.11,
3.12, 3.13)
Students will additionally have to meet
any planning conditions placed on the
construction activities, including limiting
environmental damage and waste. (3.9)
Construction
Students, working under the supervision of
experienced personnel from the employers,
will carry out the construction in accordance
with their planning. They will undertake
simple construction tasks themselves (e.g.
laying bricks, building rammed earth walls,
etc), and will direct experienced operatives
wherever plant is needed for lifting or moving
materials. (3.14, 3.10) Students must also
implement a QA system and assess the
quality of construction and snag the works
as the project proceeds. (3.12)
Safety
In planning and carrying out the construction
activities the students will have to ensure that
everything is safe. The risks they will have
to address, in addition to those common to
all sites, include working at height, working
with heavy materials, temporary stability
and more. Students will gain experience of
producing risk assessments and method
statements and will be judged on their
quality. There will be an impromptu visit from
a HSE/health and safety inspector during
construction to ensure that the students are
working in accordance with their method
statements. They will also learn about what
plant is needed and appropriate for certain
tasks. (3.5, 3.13)
Buildability
Students will gain experience of building
in a range of different materials. They will
experience the inherent pros and cons of
each material, as well as learning how to
best arrange things to limit any difficulties
that come with the different materials. They
will research each material and have the
opportunity to tailor their plans to them,
but are very likely to learn first-hand the
frustrations of poor planning or design
appropriate to the materials being used.
(3.3, 3.14)
Team work
Students will work in teams of up to 25
people split into smaller groups working
on specific parts of the project. These are
fairly large teams, so the students will have
to learn how to arrange themselves to
effectively complete the tasks before them,
and will have to use a range of tools to
manage their work. (3.11).
The Eco-house A practical design and build project for construction UTCs July 2014
The Eco-house A practical design and build project for construction UTCs July 2014
Stage 3: Construction.
Construction will commence if
the plans have been signed off.
Students will either do construction
themselves or direct trained
operatives where appropriate.
Stage 4: Construction & QA
Construction will continue Students
will review their programme of
works, method statements and risk
assessments, as necessary, based upon
their experience gained during earlier
construction. They can snag the quality
of their own workmanship.
Stage 5: Completion
Students will continue with construction,
taking into account any lessons learnt
from their review. With pressure
mounting to complete the project on
time, there can be a HSE inspection
to ensure students are working
in accordance with their method
statements. The project will culminate
with a tour and reception for the client,
and an announcement of which team
has produced the best product and most
impressed the investors.
The Eco-house A practical design and build project for construction UTCs July 2014
2
3000
3000
3000
S100
S500
P3
CH1
3000
CH1
4A
S500
CH1
P2
3000
P3
C
1
C
1
CH1
CH1
20
C
1
FORCE AT BASE OF
COLUMN REFERENCE
3000
S500
43
43
43
C
1
CH1
3000
CH1
P2
CH1
P1
20
CH1
P2
C
1
C
1
LOCATION OF COLUMN
CH1
3000
3000
P3
P2
CH1
C
1
C
1
20
FOUNDATIONS TO
CONTRACTORS DESIGN
C
1
3000
CH1
P3
FOUNDATION PLAN
LEVEL 0 PLAN
1 : 50
1 : 50
3000
3000
TOS +6.000 m
LEVEL-02
6.000
C1
SPLICE LOCATION
S500
S500
S500
TOS +3.175 m
TOS +3.000 m
LEVEL-01
B2
B2
C1
SLAB TO BE
DESIGNED TO SUIT
LOCAL GROUND
CONDITIONS
B1
C1
B2
3.000
B1
C1
4
S500
SSL +0.000 m
LEVEL-00
0.000
SECTION A
1 : 50
The Eco-house A practical design and build project for construction UTCs July 2014
The Eco-house A practical design and build project for construction UTCs July 2014
10
The Eco-house A practical design and build project for construction UTCs July 2014
11
The Eco-house A practical design and build project for construction UTCs July 2014
12
Appendix A:
Curriculum Mapping
This appendix presents the detailed mapping
of the learning points for the two Eco-house
projects. The table shows xx for learning
points which are the primary focus of one or
more of the activities included in the project,
and x for any learning points which are
addressed by the associated tasks with
each of the activities. Learning points which
are not addressed by the activities of these
two projects are to be addressed by one of
the three other key stage 5 projects (Town
Planner, Civil Engineer, Developer).
No.
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
The Eco-house A practical design and build project for construction UTCs July 2014
D&B contractor 2
13
No.
3.2
3.2.1
3.2.2
3.2.3
3.3
3.3.1
xx
3.3.2
xx
3.3.3
xx
3.3.4
xx
3.3.5
xx
xx
xx
3.3.6
3.3.7
D&B contractor 2
The Eco-house A practical design and build project for construction UTCs July 2014
xx
xx
14
No.
Key Stage 5:
Eco-House
D&B contractor 1
3.4
3.3.7
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
xx
D&B contractor 2
xx
xx
xx
xx
xx
The Eco-house A practical design and build project for construction UTCs July 2014
xx
xx
15
No.
3.6
3.7
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.7.1
3.7.2
3.7.3
xx
3.7.4
3.7.5
3.7.6
3.7.7
3.7.8
The Eco-house A practical design and build project for construction UTCs July 2014
D&B contractor 2
xx
xx
16
No.
3.8
3.9
D&B contractor 2
xx
The Eco-house A practical design and build project for construction UTCs July 2014
17
No.
3.10
3.11
3.12
3.10.1
3.11.1
D&B contractor 2
3.12.1
3.12.2
The Eco-house A practical design and build project for construction UTCs July 2014
xx
xx
xx
18
No.
3.13
3.14
3.15
3.13.1
3.13.2
3.14.1
3.15.1
D&B contractor 2
xx
xx
xx
The Eco-house A practical design and build project for construction UTCs July 2014
19
No.
3.16
3.17
3.16.1
xx
3.16.2
xx
3.16.3
xx
3.17.1
3.17.2
3.17.3
The Eco-house A practical design and build project for construction UTCs July 2014
D&B contractor 2
20
No.
3.18
3.19
3.18.1
xx
3.18.2
xx
3.18.3
3.18.4
3.18.5
3.18.6
3.19.1
3.19.2
3.19.3
3.19.4
The Eco-house A practical design and build project for construction UTCs July 2014
D&B contractor 2
21
No.
3.20
3.20.1
Evaluate the role of asset management in the economic
and social development of the built environment. This
provides learners with the opportunity to analyse, evaluate
and explore principles and practices in relation to the
management of built assets to achieve economic and
3.20.2
social benefits.
3.20.3
3.20.4
3.21
3.21.1
3.21.2
D&B contractor 2
3.21.3
Identify and evaluate the contribution of protecting the
built environment to social and community objectives
The Eco-house A practical design and build project for construction UTCs July 2014
22
12.0 Appendix B:
Quantity Estimates
This appendix presents an initial estimate
of the quantities of materials required for a
selection of the different possible materials
to be used in the exercise. This is based on
the material being used to provide infill for a
single 3m wide bay of the steel frame.
Unit size
Task
Material
Width
Height
Area (m)
Width
Height
Quantity
Brick
2.4
7.2
0.215
0.103
0.075
14
32
448
Block
2.4
7.2
0.45
0.1
0.225
11
77
Insulation
2.4
7.2
1.2
0.05
2.4
Wall Ties
2.4
7.2
0.9
0.45
35
Excluding openings.
L Ties (Debonded)
2.4
7.2
0.45
14
Head Restraint
2.4
7.2
0.9
DPC
3m
300mm thick
rammed earth wall
2.4
7.2
0.3
2.5m
DPC
3m
2.4
7.2
0.45
12
Nuts
12
10mm Rebar
(1.44m)
1.5
2.4
3.6
0.2
12
26
Rammed Earth
The Eco-house A practical design and build project for construction UTCs July 2014
Comments
Assumptions
23
12.0 Appendix B:
Quantity Estimates
Unit size
Task
Material
Width
Height
Area
(m)
Width
Height
Quantity
Comments
2.4
7.2
0.6
2.4
7.2
Insulation
2.4
7.2
0.6
0.05
1.2
10
DPC
3m
Sheathing Plywood
Sheet (12mm)
2.4
7.2
2.4
0.012
1.2
7.2m
Breathable membrane
2.4
7.2
7.2m
25x50mm timber
studwork (2.4m)
2.4
7.2
0.6
600mm centres
External timber
cladding
2.4
7.2
0.018
0.144
17
18
Nails
Pack of 500
Straw Bale
2.4
7.2
0.35
0.45
18
Method of construction
to be advised by
specilaist contractor
Render
2.4
7.2
0.05
0.5m
DPC
3m
Proprietary panel
2.4
7.2
1.5
0.15
1.2
Proprietary system
to be selected, and
hence construction
methodology dependent
upon this decision
Mullions/post
2.4
7.2
2.4
Head flashing
2.4
7.2
1.6
Cill flashing
2.4
7.2
1.6
The Eco-house A practical design and build project for construction UTCs July 2014
Assumptions
24
Appendix C
Eco-house teacher
support information
Overview
This appendix is intended to provide support
material that will help teachers develop
resources to deliver the stages of the ecohouse project. In addition to the information
in this appendix, teachers should refer also
to the construction drawings and design
specification provided by Expedition for the
eco-house structure.
Introduction
All floor systems presented are based on
a typical 3m bay of the steel frame; all wall
systems proposed are based on a 3x3m bay
of the steel frame, supported at ground level
and designed to withstand a wind pressure
assumed as 1.15 kN/m2.
Students will be able to choose from
a palette of available materials:
Floors
Precast concrete panels;
Walls
Cavity wall;
Timber frame wall;
Light steel frame wall;
Rammed earth wall;
Structural Insulated Panels;
ModCell wall panels;
Straw bale wall.
The Eco-house A practical design and build project for construction UTCs July 2014
25
Precast concrete
floor panel
Data sheet
1. Introduction
Largely because of fast on-site construction,
precast floor units are one of the most
economic flooring solutions for the widest
variety of situations including masonry, steel
and concrete structures for retail, commercial
and industrial buildings. Available as
prefabricated panels, the units are
manufactured under strict quality-controlled
conditions and can be quickly lifted and
assembled on site. Fitting of precast is a
fast process and not subject to the same
weather dependency as traditional
construction methods.
Pre-fabrication enhances quality control due
to offsite manufacture, thereby reducing the
risk of on-site workmanship problems. The
floor panels thermal mass can reduce the
need for air conditioning whilst providing
good acoustic performances and fire
resistance. Solid precast planks are typically
used for shorter spans (as in our case);
voided floor units are suitable for longer
spans to reduce the quantity of materials in
line with sustainability aims and to permit
easy distribution of services within floor and
ceiling zones.
2. Design activities
Precast floor panels can either come as
off-the shelf elements or be specifically
manufactured following the designers
instruction. In this case, the panels must
be procured from a precast concrete
manufacturer following the design specified
in this report to suit the frame geometry
and the end connection requirements.
The students can investigate the available
products, considering the frame geometry,
typical span to depth ratios and maximum
allowable loads. They can design one
floor unit of solid reinforced concrete that
they can afterwards build on site. Carrying
out this design exercise, the students can
understand the load distribution on the floor,
the interaction between steel and concrete,
the material properties, the typical loads
for various usage of the building. They can
design the floor panel to resist bending and
shear actions and typical span to depth ratios
to limit deflections.
Applied loads:
Self-weight: SW=25kN/m3x0.2m=5kN/m2
Superimposed Deal Load= 0.75 kN/m2
Imposed Load=4.2kN/m2 (3kN/m2 imposed
load + 1.2kN/m2 allowance for partitions)
Factored line load at ultimate limit state:
q=(1.35x(SW+DL)+1.5xIL)
x(Width)=(1.35x(5+0.75)+1.5x4.2)
x1m=14kN/m
The Eco-house A practical design and build project for construction UTCs July 2014
26
The Eco-house A practical design and build project for construction UTCs July 2014
27
3. Construction activities
The students can build their own panel on
site, preparing the formwork, placing the
reinforcement and pouring the concrete
depending on the schools risk assessment.
They will cast in the concrete the lifting
inserts to allow the panel to be lifted once
it reaches the required strength. If all the
panels are pre-made, the students will be
involved with the lifting sequence, under
the supervision of trained personnel and
full personal protective equipment.
4. Options
4.1. Minimum requirements
The panels must be designed as described in
the previous section and have to be procured
from a precast concrete manufacturer. The
panel thickness must be not less than the
proposed 200mm.
4.1.1. Connection details: Notched ends
The panels need to be notched at the ends
to allow for a safe and easy connection to
the steel beam (see sketch for more details).
This allows for a quick installation with no
need of the structural concrete topping
poured on site to connect the panels that
is normally required for the typical panel
connection.
4.2. Optional additions:
The school can choose if the students can
build one floor unit on site or if all the panels
will be pre-made and delivered on site ready
to be installed, depending on the schools
risk assessment.
The Eco-house A practical design and build project for construction UTCs July 2014
28
Cavity wall
Data sheet
1. Introduction
Cavity walls consist of two 'skins' separated
by a hollow space (cavity). The skins are
commonly masonry such as brick or concrete
block. Masonry is an absorbent material, and
therefore will slowly draw rainwater or even
humidity into the wall. The cavity serves as
a way to drain this water back out through
weep holes at the base of the wall system
or above windows. The cavity also improves
the thermal performance of the wall and
allows insulation to be installed (although
that insulation shouldnt completely fill the
cavity). The two leaves of the wall are tied
together with wall ties, which allow the wall
to act as one, giving it much more stability
than it would otherwise have.
The Eco-house A practical design and build project for construction UTCs July 2014
29
2. Design activities
The students can familiarize with a traditional
construction technique, understanding
the external actions applied to the wall
(selfweight of the system and lateral
wind load of 1.15kN/m2), the material
properties and the resistance required.
They will choose the brick and block from
a selection of existing products and will
come to understand the role of the cavity
in controlling the humidity in the internal
spaces. The wall system consists of 140mm
thick internal blocks, an insulation layer, a
50mm cavity and 100mm thick outer bricks.
3. Construction activities
The students should build the masonry
wall following the traditional construction
sequence, positioning the first layers of block
works and brickworks and securing them
with mortar. After building up the first stage
of one leaf of masonry (either external or
internal) to include the first row of ties above
the commencement of the insulation, the
students will position the insulation layer
against the masonry so that the wall tie drips
are halfway across the top edge of the slabs.
The following leaf is then built to the top level
of the insulation.
4. Options
4.1. Minimum requirements
For the wall to be a stable system, the
students must build the two inner and outer
skins, properly connected with ties. The
double skins and the ties act as a frame in
their plane and provide an increased lateral
stability to the wall system with respect to a
single skin wall solution. The students must
connect the wall to the steel frame via top
and lateral restraints as described in the
following sections. The masonry wall can be
designed as a simple full-height wall without
openings as basic solution.
The Eco-house A practical design and build project for construction UTCs July 2014
30
Image: www.ancon.co.uk
The Eco-house A practical design and build project for construction UTCs July 2014
31
Image: www.ancon.co.uk
Image: www.ancon.co.uk
Image: www.ancon.co.uk
The Eco-house A practical design and build project for construction UTCs July 2014
32
Image: www.ancon.co.uk
The Eco-house A practical design and build project for construction UTCs July 2014
33
6. Construction notes
The Eco-house A practical design and build project for construction UTCs July 2014
34
The Eco-house A practical design and build project for construction UTCs July 2014
35
2. Design activities
The students can familiarize with a traditional
construction technique such as timber
framing. They can search for existing typical
timber frames geometries, stud sections and
spacing depending on the external actions
applied to the wall (self-weight of the system
and lateral wind load of 1.15kN/m2), material
properties and resistance required.
Students can also get in contact with
manufacturers to obtain technical details
of the available prefabricated frames.
The proposed wall system is a standard
frame with 100x50mm C16 timber studs
at 400mm spacing with insulation between
the studs. In-plane stability is provided by the
external plywood sheathing. Internally, the
wall is covered with a vapour-control layer
and plasterboard.
Externally, the timber frame has a layer
of plywood sheathing, vapour permeable
membrane, 50mm cavity and various
cladding options. The proposed cladding
is a timber boarding. The students can learn
about thermal and structural behaviour of the
system, together with fire resistance
and condensation control methods.
The timber frame wall can be designed
without openings as initial simple example;
afterwards the students can design the wall
to allow for optional openings and compare
the results. At the end of the design stage,
the students can plan the construction
sequence and calculate the quantities
of materials needed to proceed with
the construction phase. As final task,
the students can also consider the weight
of the wall system and the overall cost
3. Construction activities
On site, the students can assemble the
timber frame following their design and
lift it in place under the supervision of
experienced personnel. The students can
start with a simple solution without openings,
with timber studs and plywood sheathing
only. Insulation, vapour control membrane,
plasterboard and external cladding are not
essential for the wall, but could be a valuable
additional learning point. If a window is
included, students should make sure that the
opening is properly framed with horizontal
and vertical studs. The students have to
provide adequate fixing of the wall to the
primary structure. Precast channels installed
in the concrete base provide an easy
connection at the base of the wall, avoiding
drilling operations on site. The frame needs
to be connected to the steel beam at the top
end via nails 6mm in diameter positioned
at 200mm spacing.
4. Options
4.1. Minimum requirements
For the wall to be a stable system, the
students must position the vertical studs at
the required spacing, connected at top by
the head plate and at the bottom by the sole
plate. To provide in-plane stability to the wall,
the students must install plywood sheeting
(sheathing quality). The timber frame wall
can be designed as a simple full-height wall
without openings as basic solution. The
students must connect the timber frame to
the steel frame via top and lateral restraints
as described in the following sections.
The Eco-house A practical design and build project for construction UTCs July 2014
36
6. Construction notes
4.2.2. Openings
If openings are included, the allowable
opening is restricted to a maximum of
630x1050mm. Adequate framing of the
opening and provision of timber lintel is
required (refer to manufacturers details
or contractors instructions on site).
The Eco-house A practical design and build project for construction UTCs July 2014
37
The Eco-house A practical design and build project for construction UTCs July 2014
38
2. Design activities
The students can familiarize with a traditional
construction technique such as a lightweight
steel wall system. They can search for
existing typical steel frames geometries,
stud sections and spacing depending on
the external actions applied to the wall
(self-weight of the system and lateral wind
load of 1.15kN/m2), material properties
and resistance required. Students can
also get in contact with manufacturers to
obtain technical details of the available
prefabricated frames. The proposed wall
system is a standard frame with C-section
vertical studs (100x50x1.2 C profiles- see
http://www.kingspanprofiles.com/Products--Solutions/Kingframe.aspx ) at 600mm
spacing with insulation between the studs.
Two U-shaped top and bottom tracks
connect and restrain the vertical studs
(104x55.5x1.2 U-channel).
In case of internal wall, the steel frame
has one layer of plasterboard on each
side. In case of external wall, additional
insulation and render layer can be applied.
The students can learn about thermal and
structural behaviour of the system, together
with fire resistance and condensation control
methods. The steel frame wall can be
designed without openings as initial simple
example; afterwards the students can design
the wall to allow for optional openings and
compare the results. A single C or U section
is required to frame the opening. At the end
of the design stage, the students can plan
the construction sequence and calculate the
quantities of materials needed to proceed
with the construction phase. As final task,
the students can consider the weight of the
wall system and the overall cost (considering
materials, transportation and construction
equipment) comparing this solution with the
other proposed wall systems.
3. Construction activities
On site, the students can assemble the
steel frame following their design and lift it in
place under the supervision of experienced
personnel. The students can start with
a simple solution without openings, with
vertical steel studs connected by top and
bottom U-channels. Insulation, vapour
control membrane and plasterboard are
not essential for the wall, but could be
a valuable additional learning point. If a
window is included, students should make
sure that the opening is properly framed with
single horizontal and vertical C-studs. The
students have to provide adequate fixing
of the wall to the primary structure. Precast
channels installed in the concrete base
provide an easy connection at the base of
the wall, avoiding drilling operations on site.
The frame needs to be connected to the
steel beam at the top end via nails 6mm in
diameter positioned at 200mm spacing.
4. Options
4.1. Minimum requirements
For the wall to be a stable system the
students must position the vertical C-studs at
the required spacing, connected at top and
bottom ends by U-channels. The steel frame
wall can be designed as a simple full-height
wall without openings as basic solution. The
students must connect the lightweight steel
frame to the structural steel frame via top
and bottom restraints as described in the
following sections.
4.1.1. Wall connections details
4.1.1.1. Head restraint
Pre-drilled 8mm holes are provided
in the beams flanges to connect the
lightweight steel frame to the primary
structure via nails 6mm in diameter
positioned at 200mm spacing. The nails
also guide the students positioning and
installing the steel frame wall.
The Eco-house A practical design and build project for construction UTCs July 2014
6. Construction notes
Risks and minimum requirements
Ensure that the lightweight steel frame is
restrained at its top and bottom edges as
specified in section 4.1.1 in order to have
a stable wall system.
If any opening is included, ensure that
the opening in the wall do not exceed the
dimensions provided in section 4.2.3.
School to provide an appropriate
scaffolding system and full personal
protective equipment to every student
and every person who attends site during
construction.
Particular attention is needed when
lifting the wall into position. Contractor to
provide stability in temporary conditions
during the construction sequence.
During construction, the helfen channels
cast in the concrete base must be
covered or protected from dust infiltration
when not used to connect the wall
system to the ground.
39
2. Design activities
The students can familiarize with a
construction technique that was probably
introduced to Britain by the Romans and has
been used in the UK for around 2000 years.
They can analyze case studies of existing
buildings and various examples available
in literature (the most significant period of
construction followed the reintroduction
of this technique into the UK in the early
nineteenth century, after a revival of interest
in France). The students can design the
rammed earth wall as external cladding or as
a freestanding internal wall, understanding
the actions applied to the wall, the material
properties and resistance required. The
maximum wall slenderness for walls
restrained along the edges is H/t<12, for
freestanding internal walls is H/t<8. The
proposed wall system for both the solutions
is 375mm thick minimum. For external walls,
the bending induced by the wind acting on
the wall is calculated as follows:
The design resistance of rammed earth walls for bending is evaluated as:
For external walls, the shear induced by the wind acting on the wall is
calculated as follows:
For external walls, the shear induced by the wind acting on the wall is
calculated as follows:
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3. Construction activities
A significant difference between rammed
earth and most other wall building materials
is that rammed earth moves straight from a
loose prepared material to a post-compacted
in-situ wall with very few intermediary
stages. Materials are prepared before
construction: loose moist soil is placed in
layers 100150 mm deep in the formwork
(used as a temporary support during soil
compaction) and rammed manually or
mechanically. Unlike with concrete, rammed
earth formwork can be removed almost
immediately after compaction, enabling
much faster re-use.
4. Options
4.1. Minimum requirements
The wall can be designed as a full-height
wall without opening with a minimum
thickness of 375mm and must be built
aligned to the secondary bays of the
primary structure.
4.1.1. Wall connections details
4.1.1.1. Head restraint
It is common practice in rammed earth
construction to provide a timber wall plate
continuously at the top of the wall. Wall
plates are usually either timber or reinforced
concrete. The proposed wall plate is a C16
timber plate 100x50mm fixed to the rammed
earth wall using anchorage bolts 600mm
long positioned at 500mm spacing.
4.1.1.2. Bottom connection
Footings for rammed earth walls follow
design and construction provisions for
similar solid masonry walls. Protection
from water damage, moisture ingress and,
in appropriate areas, radon gas, is the
governing criteria for wall footing details.
Where possible the damp-proof course
should be made continuous with the damp
proof membrane, as is common practice.
During construction, the helfen channels
cast in the concrete base must be covered
or protected from sand penetration.
The Eco-house A practical design and build project for construction UTCs July 2014
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The Eco-house A practical design and build project for construction UTCs July 2014
42
6. Construction notes
School to provide formwork
and compacting tools for
construction sequence.
School to provide an appropriate
scaffolding system and full personal
protective equipment to every student
and every person who attends site
during construction.
The Eco-house A practical design and build project for construction UTCs July 2014
43
SIPs
Data sheet
1. Introduction
Structural insulated panels SIPs, are a
composite building material. Theyre are
prefabricated, high performance, lightweight,
building panels that can be used in floors,
walls and roofs for residential
and commercial buildings.
SIPs are manufactured under closely
controlled factory conditions and can be
custom designed for each application. They
consist of an insulating layer of rigid core
sandwiched between two layers of structural
board. The board can be sheet metal,
plywood, cement, magnesium oxide board
(MgO) or oriented strand board (OSB) and
the core either expanded polystyrene foam
(EPS), extruded polystyrene foam (XPS),
polyurethane foam or composite honeycomb
(HSC). SIPs share the same structural
properties as an I-beam or I-column.
The rigid insulation core of the SIP acts as a
web, while the sheathing fulfils the function
of the flanges. Their high insulation and
airtightness reduce the major sources of
building energy use, making them one of the
greenest construction materials. The result
is a building system that is extremely strong,
energy efficient and cost effective. The high
strength and low weight of SIPs allow large
sections of building to be lifted in one piece
for speed of erection but the panels may
also be erected one at a time by hand
where access is restricted.
2. Design activities
Panels are prefabricated by the
manufacturer, either from pre-designed
plans or a customized layout. The students
can search for available products,
understanding the structural behaviour of
the SIPs in resisting external loads, airtightness performance, thermal and fire
resistance properties. Students should end
up selecting a manufacturer to procure
SIPs panels suitable for a wind load of
1.15kN/m2. The design of the panels must
comply with top connection via nails and
bottom connection via helfen channels.
The proposed wall system is a 150 mm
thick wall, but the students must consult
the system manufacturer to confirm system
specific details. For this wall solution, all
openings should follow the manufacturers
specifications. The students can plan the
construction sequence and calculate the
quantities of materials needed to proceed
with the construction phase. As final task,
the students can calculate the weight of the
wall system and the overall cost (considering
materials, transportation and construction
equipment) comparing this solution with the
other proposed wall systems.
The Eco-house A practical design and build project for construction UTCs July 2014
3. Construction activities
Panels are shipped to the site and
assembled. Typically, the complete system
is delivered to site ready for erection. The
panels are lightweight, quick to erect and
free from the problems of compression
shrinkage and cold bridging associated with
other forms of construction. The students can
lift the panels in place under the supervision
of experienced personnel,depending on the
schools risk assessment.
4. Options
4.1. Minimum requirements
As a simple initial solution, the panels can be
designed to create a full-height wall without
openings. All connection details should be as
per manufacturers specifications.
4.1.1. Wall connections details
4.1.1.1. Panels connection
Panels are jointed using either solid
timber within the ends of the panels or SIP
based insulated splines, depending on the
manufacturers specific system. Timber
fillets are normally used when additional
strength is needed (not necessary in this
case). The splines are fixed into the ends
of the panels using either nail, screw or
bolt fixings and sealed.
44
4.2.2. Openings
Once the panels have been manufactured,
openings can be formed. These can either
be in the form of small framing panels that
are site assembled to form the opening,
or cut from a large blank wall panel.
Solid timber lintels, studs and rails are
normally inserted around the perimeter
of the opening into the core of the panel.
These timbers support any imposed
loads from above and provide a solid
fixing for the installation of window or
door sets. If any opening is inserted,
consult the system manufacturer to
confirm opening specific details.
The Eco-house A practical design and build project for construction UTCs July 2014
6. Construction notes
School to provide full personal
protective equipment to every
student and every person who
attends site during construction.
Particular attention is needed when
lifting the wall panels into position.
Contractor to provide stability in
temporary conditions during the
construction sequence.
Ensure that the wall system is
properly connected top and bottom
to the primary structure via nails
and halfen channels as per
manufacturers specifications.
If any opening is included, follow
manufacturers specifications.
During construction, the helfen
channels cast in the concrete base
must be covered or protected from
dust infiltration when not used to
connect the wall system to the ground.
45
ModCell
Data sheet
1. Introduction
ModCell allows super-insulated, highperformance, low energy passive buildings
to be built using renewable, locally sourced,
carbon sequestering materials that include
straw bale and hemp to create a less than
zero carbon construction system. The
structural timber frame is infilled with
locally sourced straw bales, which are
stacked to form a wall, pre-compressed to
reduce settlement and then held together
for stability. The wall is then either plastered
using a protective render or closed with
breather and then clad with a range of
products, including timber cladding.
The bales act compositely with the render
to provide a stiff panel that resists wind
loads. This provides a sustainable form of
construction with minimal use of materials
and low embodied energy.
2. Design activities
Panels are prefabricated by the
manufacturer, either from pre-designed plans
or a customized layout. The students can
familiarize with this innovative construction
technique, understanding the behaviour
in resisting external loads, air-tightness
performance, thermal and fire resistance
properties. Students should end up procuring
ModCell panels suitable for a wind load
of 1.15kN/m2. The design of the panels
must comply with top connection via 6mm
diameter nails at 200 mm spacing and
bottom connection via helfen channels.
The proposed wall system is a ModCell
traditional panel 480mm deep, but
the students must consult the system
manufacturer to confirm system specific
details (see http://www.modcell.com ). For
this wall solution, all openings should follow
the manufacturers specifications. The
students can plan the construction sequence
and calculate the quantities of materials
needed to proceed with the construction
phase. As final task, the students can
calculate the weight of the wall system and
the overall cost (considering materials,
transportation and construction equipment)
comparing this solution with the other
proposed wall systems.
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3. Construction activities
ModCell traditional panels are 480mm
deep and delivered to site with a two coat
render finish applied inside and out. A finish
skim coat is applied on site from a scaffold
or cherry picker as the final surface finishes.
ModCell panels can be lifted into position
on site using a telescopic arm or crane.
Panels are sealed using a range of airtight
tapes. The students can lift the panels
in place under the supervision of
experienced personnel, depending
on the schools risk assessment.
4. Options
As a simple initial solution, the panels can be
designed to create a full-height wall without
openings. All connection details should be as
per manufacturers specifications.
4.1. Minimum requirements
4.1.1. Wall connections details
4.1.1.1. Head restraint
The manufacturers panels design should
comply with a head connection to the
primary structure via nails 6mm in diameter
positioned at 200mm spacing to suit the
pre-drilled 8mm holes provided in the primary
beams flanges.
4.1.1.2. Bottom restraint
The manufacturers design of the bottom
connection should comply with the use of
Halfen channels precast in the concrete
base. Simple twist-in T-bolts can be adjusted
along the length of the channel giving
versatile anchoring positioning. The channel
provided are Halfen HTA-CE 38/17 and
come together with the T-bolts to be used
to connect the panels on site to the channel.
The Eco-house A practical design and build project for construction UTCs July 2014
47
Straw bale
Data sheet
1. Introduction
Wall sketch
Straw bales have been used to construct
buildings since the middle of the 19th century
with the advent of the baling machine.Today,
straw bale is used in modern construction
because of its excellent thermal properties
and its low environmental impact. Straw is
a renewable material that can be replaced
by natural processes at a rate comparable
or faster than its rate of consumption
by humans.
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48
2. Design activities
The students can familiarize with this
innovative construction technique,
understanding the current use in modern
construction, structural and thermal
performances and related advantages
and disadvantage. Students can also
get in contact with manufacturers to
obtain technical details of the available
prefabricated frames.
The proposed wall system is a timber frame
with two 100x50mm lateral studs (framing
the straw bales) connected by a top plate
and sole plate. The straw bales are used
as infill, laid using a stretcher bond format.
The students can plan the bale arrangement
and work out the number of layers required.
They can also develop the base connection
details, considering wooden spikes at
approximately 450 mm centres rising about
250 mm from the base plate of the wall to
secure the first course of bales.
It is suggested to pin the bales together with
wooden spikes, to increase the robustness
of the wall. The pins should intersect four
courses of bales (see wall sketch), locking
them together. To provide in-plane stability
and rainscreen protection, the student should
choose an appropriate render layer. The
suggested render is a lime render applied
on site.
3. Construction activities
The students can assemble the timber frame
under the supervision of qualified personnel
and connect it to the primary steel structure.
As in the case of the timber frame wall, the
top connection is done via 6mm nails and the
bottom connection via channels cast in the
concrete base.
It is usual practice for the first course of
bales to be secured onto wooden spikes at
approximately 450 mm centres rising about
250 mm from the base plate of the wall. The
timber spikes ensure that the foot of the wall
does not slip. Once the first course of straw
bales has a secure footing, the student can
stack the bales without any bonding agent or
mortar using a stretcher bond format, ie each
bale centred on the bale joint. It is suggested
to pin the bales together with wooden spikes,
to increase the robustness of the wall. The
pins should intersect four courses of bales
(see wall sketch), locking them together.
The Eco-house A practical design and build project for construction UTCs July 2014
49
4. Options
4.1. Minimum requirements
The straw bale wall requires the external
timber frame with wooden spikes rising
from the base to secure the first course of
bales. The frame should be firmly connected
to the primary steel structure to provide a
stable structure. The straw bale layers must
remain in state of compression to avoid any
settlement after construction.
4.1.1. Internal and external cladding
Although not necessary for stability
(providing that the bales are left in state of
compression), the lime render is needed as a
rainscreen protection for the straw bale.
4.1.2. Wall connections details
4.1.2.1. Head restraint
Pre-drilled 8mm holes are provided in the
beams flanges to connect the lightweight
steel frame to the primary structure via
nails 6mm in diameter positioned at
200mm spacing. The nails also guide
the students positioning and installing
the steel frame wall.
The Eco-house A practical design and build project for construction UTCs July 2014
50
THINK UP
FIRST FLOOR
MORLEY HOUSE
320 REGENT STREET
LONDON W1B 3BB
T +44 (0)20 7307 6520
E INFO@THINKUP.ORG
W WWW.THINKUP.ORG
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