Simple in concept, yet extremely effective in application, the colour coding system aims to meet the modern construction industry’s need to improve productivity whilst maintaining site safety and better quality workmanship.

Using different colours to identify the different gauges of SFS section, the system is introduced at the earliest possible stage of the design process, where sections are colour coded on the project’s drawings. The same colour codes are then applied to the corresponding sections during manufacture and incorporated within the installation instructions.

When the SFS sections are delivered to site, installation operatives can quickly and easily identify the sections against the drawings by matching colours, making the whole process more efficient and less liable to error.

Steve Ginger, sales director at Metsec’s Framing Division, comments, “Installing the wrong gauge of section in the wrong place can have disastrous consequences. Colour coding virtually eliminates the risk of this happening and makes component identification so simple for the Sub-Contractor.

“We believe we are the first company in our field to implement a colour coding system and it illustrates our commitment to providing both main contractors and sub-contractors with the means to operate safely and profitably.”

Further details on SFS and other Metsec products can be found at www.metsec.com, by contacting Metsec on 0121 601 6000 or emailing interactive@metsec.com.

Part of the £30 million redevelopment of Warwickshire County Cricket Club, the new stand will provide seating for some 8,250 spectators as well as providing world-class hospitality and media facilities. It also adds an attractive, modern face to the ground, with a stunning blue façade rising above the surrounding area to create an eye-catching feature.

Needing to provide a bar and catering concession on one of the new stand’s curved upper terraces, contractors Galliford Try opted for Metsec’s SFS lightweight steel framing system, confident that it would not impose undue loads on the terrace slab and that it would be able to provide the column-free openings of up to 8 metres that were required in the area, which will be subject to large volumes of spectators during peak periods.

At street level, the main entrance is protected by the overhanging structure of the stand itself, supported by four structural columns housed behind fin-shaped, cladded box sections, the unusual shape adding to the stand’s aesthetic appeal. Again, Metsec SFS was chosen as it not only provided the versatility to create the raked sections, but also the strength required to withstand crowd pressures as spectators enter and exit the ground.

Commenting on the selection and use of Metsec’s products, David Parsons, Design and Construct Co-ordinator at Galliford Try, states, “The steel framing solutions from Metsec came just at the right time; they provided the performance and functionality we needed in the particular areas, but just as importantly, their speed of installation ensured that our construction programme remained on schedule.”

Installation of SFS was undertaken by Stafford-based specialists, ISEC Interior Systems.

Further details on SFS and other Metsec products can be found at www.metsec.com, by contacting Metsec on 0121 601 6000 or emailing interactive@metsec.com.

The projects, currently being undertaken in the Stoke-on-Trent and Derby areas, comprise a mixture of special educational needs and secondary education establishments of various designs, with a total value of £145 million The emphasis is not only on providing the right facilities to a high standard, but also on delivering value for money for the Local Authorities.

From the very start, Balfour Beatty assembled a team of specialists and preferred suppliers to assure success and maximise benefits in terms of efficiency and cost control. Metsec was appointed during this process not only to manufacture and deliver the steel framing systems required, but also to provide design expertise.

Working with structural engineers, architects and structural steel contractors, Metsec’s designers attended meetings and workshops aimed at developing design solutions which would streamline the construction process to maximise efficiency and, where possible, make cost savings.
The early involvement of Metsec’s in-house design team has not only delivered cost savings across all of the projects completed to date, but has helped to assure the accuracy of the designs. This, in addition to the company’s knowledge of installation techniques and close working relationships with specialist steel contractors has foreseen possible problems in the construction process and eliminated them before they occur.

Colin Harper, Project Director at Balfour Beatty Construction, comments, “As with any project, it is vital to assure accuracy, risk reduction and cost control as well as delivering value for money for the client. Getting Metsec involved at the earliest stages of conceptualisation made them a key part of the design team and has already paid dividends in these crucial areas.

“Thanks to the benefits that have already been realised, we certainly believe that this approach signals a new phase in the development of good practice within Balfour Beatty, and where we lead others are certain to follow.”

Three of the schools in Stoke and two in Derby are due for completion in 2012. A further four schools in Stoke will be completed in 2013 and the two remaining Stoke schools are scheduled for handover the following year.

Further details on Metsec’s SFS lightweight framing system and other Metsec products can be found at www.metsec.com, by contacting Metsec on 0121 601 6000 or emailing interactive@metsec.com.

Metsec view the complete system as being far more than the high performance, lightweight steel framing components that make up the SFS product; it also includes the value engineered design and fully detailed drawings, prepared by the steel suppliers’ technical team, the full range of standard and bespoke accessories, available for completeness of installation, together with the expert sales and technical support provided from initial consultation through to final installation.

Structural engineering expertise and vast practical construction experience have enabled Metsec’s design teams to create an innovative approach to the design of structural openings. The prime objective with every project is to deliver a solution that meets all of the performance requirements, whilst maximising the economic benefits of efficient design and installation. This allows Metsec to significantly reduce the overall weight of steel at design stage, without sacrificing the building’s functionality, appearance or performance. The result is a more efficient and cost-effective solution. The ‘free design’ services offered by some suppliers rely on over-engineered design solutions which can increase the overall weight and value of steel used, resulting in an uneconomic solution for both the installer and main contractor.

SFS epitomises Metsec’s drive to lead the way in lightweight steel construction solutions by meeting the industry’s need for time, cost and production efficiency. Official recognition of this comes from the Faithful and Gould report, which concluded that SFS can deliver cost savings of up to 39% over traditional block work in the construction of inner leaves of external walls.

SFS also continues to evolve and improve through Metsec’s research and development initiatives. New product innovations, such as the slotted head deflection track and accessories range, enhance the system’s efficiency and assure the delivery of continued benefits to the entire construction team.

Steve Ginger, sales director for Metsec’s Framing Division, comments, “Whilst SFS might appear to be a complex building product, expert solution design, coupled with approved construction drawings and a professional SFS installation company, make it a simple, straightforward system to incorporate into virtually any project.

More importantly, following this disciplined route from design through to final installation, utilising the expertise of our own in-house design team as well as the system’s dedicated and bespoke accessories, ensures that the project benefits from the impressive time and cost savings that SFS delivers.”

Metsec provides regular monthly training days for their approved installers and ensures that the highest level of workmanship is delivered on site with the comfort and benefit of total assurance from Metsec’s comprehensive design warranty and professional indemnity insurance.

Further details on SFS and other Metsec products can be found at www.metsec.com, by contacting Metsec on 0121 601 6000 or emailing interactive@metsec.com.

The Balfour Beatty group-wide initiative has created a framework to achieve environmental and operational benefits in three key areas; health and safety (Zero Harm), the increased use of standardised components and off-site assembly, and the building of competencies through the early influence and control of the procurement process.

As part of this process, Balfour Beatty expects its preferred suppliers to embrace these objectives, contributing towards reduced waste, increased efficiency and improved economy through the creation and adoption of original working practices, which include product and service development.

The appointment of Metsec Cable Management as a preferred supplier follows lengthy and detailed assessment of the company’s manufacturing capabilities, commercial operations and ethos to ensure compliance with Balfour Beatty’s stringent requirements across all of the three key areas.

Nigel Hempsall, head of procurement at Balfour Beatty Engineering Services, comments, “Maintaining the Balfour Beatty reputation for excellence in all areas of our operations relies not only on the capabilities and commitment of our own organisation, but also those of our partners who play a vital role in enabling us to deliver on our promises. The selection process for preferred suppliers is, therefore, undertaken assiduously.

“Whilst Metsec’s pre-eminent position in the market is unquestioned, they were subject to the same rigorous, detailed examination as other suppliers to ensure they will continue to meet our requirements as we work together in the future. We are looking forward to a long and fruitful relationship that benefits the industry, the environment and both of our organisations.”

The £28m unit has been constructed by Kier London for the North East London Foundation Trust (NELFT) and will enable NELFT to rationalise some of its existing services as well as provide brand new facilities designed to deliver modern in-patient mental healthcare for the people of Barking & Dagenham, Havering and Redbridge.

The new unit will be situated adjacent to an existing building and provide five new in-patient wards over two floors, as well as a shared central hub and new entrance to both buildings. The surrounding grounds will be landscaped to provide garden areas for service users and staff.

The design for the unit, which has been created by a team of design and construction specialists, including Devereux Architects, working in partnership with service users and staff, takes into account the impact of environment on how service users feel and how staff are able to care for them. The aim has been to create an environment that promotes recovery, which current thinking suggests includes bright, colourful, light modern wards with gardens, so that service users and visitors feel optimistic about their future.

In line with the contemporary design, the new unit has been constructed using Metsec’s SFS lightweight galvanised steel infill walling rather than traditional blockwork. This forms a secondary structure which is fixed between the primary superstructure, usually at the slab edge to allow insulation and external finishes to be installed continuously outside the main structural frame.

This method of construction offers a number of advantages: It is fast and cost-effective to install, the building envelope is completed earlier in the construction cycle so that interior fit-out of the lower storeys can begin as higher storeys are created, and SFS infill walling is lighter than block work which reduces the depth of foundations required. The impact on the environment is also reduced as the steel is recyclable and infill walling can be delivered to site with considerably fewer vehicle journeys than blockwork, needs less storage space on site and requires no wet work or welding.

Research recently carried out by Faithful & Gould has demonstrated a cost saving of up to 39% when using SFS compared with traditional blockwork. The research report may be downloaded from Metsec’s website: www.metsec.com

Costing in the region of £25m, the new Roath Lock studios create a centre of excellence for the production of drama as part of the BBC’s plans to double television network production from Wales by 2016. Programmes being made in Cardiff include Casualty, Doctor Who and the Welsh-language, S4C soap Pobol y Cwm.

100 tons of Metsec purlins and side rails have been used in the creation of a distinctive 300m long main building with Gothic-style façade, inspired by some of William Burges’s designs at Cardiff Castle and Castell Coch. The new 15,800 m2 Drama Village includes television studios, ancillary accommodation and offices for use by creative media firms.

Moving the BBC’s biggest productions to Cardiff Bay will kick-start the development of the last totally undeveloped area of the Bay. Plans for a Digital Media Centre developed by Cardiff Council and the BBC have also been submitted, around which it is hoped a cluster of creative industries will spring up.

Metsec’s Purlin Division is the UK’s largest designer and manufacturer of light gauge purlins, side rails and mezzanine floor sections for use in many industrial, commercial and public sector applications. With a choice of Heavy End Bay, Butt or Sleeve fixing systems and the ability to span up to 15 metres, depending on the load, Metsec’s purlins and side rails give the building designer an economical and strong solution.

Manufactured from 450N/mm2 material for high strength and low weight, Metsec Z and C sections are cold rolled from pre-dipped steel with a G275 coating. They are available with profile heights from 142mm to 342mm, in thicknesses from 1.3mm to 3.0mm and with a full range of accessories to cater for most cladding types and designs.

Metsec’s customers are supported by the market-leading MetSPEC building shell design software, which links to the latest wind code and the BREVe database for topography – with further technical support available from the Metsec design office. The latest version, MetSPEC 12, includes design analysis to Structural Eurocode EC: Part 1.3. Users of MetCAM detailing software and some other 3D draughting systems can transfer data to Metsec electronically.

To find out more about Metsec products, call 0121 601 6000, email interactive@metsec.com or visit www.metsec.com.

Originally built in the mid-Nineteenth century, the South Acton Estate was developed extensively over a thirty-year period from 1949 into one dominated by high-rise tower blocks and has suffered from a poor reputation due to high levels of drug dealing and crime.
The current redevelopment project represents a massive investment by Ealing Borough Council to transform the large sink public housing estate into a sought after residential community that all residents are proud to live in.

Started in 2001, the redevelopment scheme is still very much an on-going project, with demolition and construction work being undertaken in phases by a variety of contracted teams. Residential development of Phase 1 of the project was completed in 2005 and the phase’s community centre opened in 2007, the same year in which Phase 2 of the redevelopment commenced.

It is in Phase 2 that Metsec SFS has been applied to great effect, being used in two multi-storey housing developments which will create in excess of 250 residential units.

Phase 2.1, a five- to eight-storey structure will provide 129 new homes, comprising 75 rented units and 54 shared ownership units, including 13 wheelchair adapted units, whilst Phase 2.2, which rises to ten-storeys, will deliver a further 127 units with a similar split of rented and shared ownership properties.

Five residential blocks, together with garages, were demolished to make way for the new affordable housing schemes, both of which are being developed by Willmott Dixon Housing (formerly innspace) who have been appointed by Catalyst Housing Association. Designs for the structures have been created by architects, PRP with construction undertaken by Willmott Dixon Housing.

Both residential buildings are of in-situ concrete frame construction, with Metsec exterior wall framework being the architects’ preferred choice to provide infill walling on all levels and facades.

Commenting on the specification process, Anthony Joyce of PRP, states, “The challenge on developments such as those at South Acton is to deliver a quality of build that also represents excellent value for the client. Metsec SFS is our preferred choice for creating infill walls on concrete frame. Not only is it quick and easy to install, providing savings over traditional blockwork, but the absence of wet trades enables the project to progress smoothly and tidily. In addition, the fact that everything is manufactured off-site and delivered ready for immediate installation enhances the appeal of the system from a sustainability viewpoint”

Structural engineers Tully De’Ath were also involved in the team which opted for the Metsec system. Dan Chisham of Tully De’Ath comments, “Metsec’s SFS framework met all of our requirements with respect to loadings and did away with any need for windposts. Its use would undoubtedly have saved time and money on the overall project.”

In all, around 7500m2 of 100mm stud and track framework was installed by specialist sub-contractor BR Hodgson over a six month period, accurately positioning studs to provide fixing points for the external cladding and render finishes, which they also installed. Clayton Nunn of BR Hodgson comments, “Installing Metsec SFS as the support structure for our façade finishes gives us excellent control of programme and production without influence from, or reliance on, other trades.”

To find out more about Metsec products and the housing projects to which it has contributed, call 0121 601 6000, email interactive@metsec.com or see www.metsec.com.

Metsec’s in-house design team has gained international recognition for its work on a new accommodation building at Britain’s oldest specialist music school.

Entered in the Special Projects category of AceCAD’s International Project Competition 2010-2011, Metsec’s designs for the five-storey, light gauge steel framed structure at Purcell School achieved a ‘highly commended’ commendation.

Commissioned by specialist steel framing installers XCL, Metsec’s designers were tasked with creating a steel framed structure which would realise the architect’s vision for the building, but also meet tight construction deadlines imposed by the forthcoming student intake. In order to minimise disruption to the school’s operation, and enhance efficiency of the project schedule, the structural steel elements were fabricated off-site and installed rapidly on delivery, achieving construction of one storey per fortnight.

In all, Metsec designed, manufactured and delivered some 20,000 cold-rolled steel members to the Purcell School project, including Metsec’s cold rolled steel ringbeam and pre-panellised roof cassettes.

Commenting on the award, Metsec’s technical director, Roger Taylor, states, “The award is a tribute to the ingenuity and skills of our design team. The Purcell School designs required the combination of various Metsec elements, together with hot rolled steel for some details, to deliver a solution which would meet the tight deadlines of the project.”

To find out more about Metsec products and the education projects to which Metsec has contributed, call 0121 601 6000, email interactive@metsec.com or see www.metsec.com.