Architectural Precast Concrete Cladding Sustainability

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1 Architectural Precast Concrete Cladding Sustainability

2 Environmental Advantages of Precast Products Off-site fabrication of precast concrete cladding offers many efficiencies and advantages over traditional methods, which benefit the environment: Panels are manufactured concurrently with site preparation. This can reduce project construction times and the impact on the local community by over 50%. Mostly, work is performed in the factory, panels benefit from manufacturing efficiencies, innovations and design flexibility. This allows panels to be stored in a safe place and reduces the number of deliveries compared to traditional construction methods. Additionally, deliveries can be co-ordinated to minimise emissions and traffic disruption. Off-site manufacturing allows work to be carried out in a controlled, comfortable and safe environment where safety requirements are much easier met and policed. Working in this environment improves quality, thus reducing defects and waste. Materials and labour can be sourced locally, thus reducing transport emissions and supporting regional economies. Getting it right from the start It s necessary to think about sustainability in buildings, but this raises practical challenges. The early stages of a project can be particularly fraught or problematic. However, decisions made at this time can affect not only the build programme, but also long-term building performance, so it is essential to get them right. Teams addressing sustainability need help to ensure that from the beginning their decisions produce the intended results. The early appointment of a precast cladding manufacturer can pay dividends because they will bring expertise, experience and insight. In practical terms, project teams will often need to liaise closely with precast cladding manufacturers to ensure that sustainability objectives are met in the long term. To be truly effective this collaboration must continue throughout the detailed design, production information and construction process. Techrete offers the full suite of services from design to manufacture and erection. That means that, from the outset, Techrete work closely with our clients to ensure optimal results.

3 Local investment Techrete invests in its local communities, and have donated to primary schools, football teams, gardening associations and local scout groups. Additionally, we have donated lump sums to charities such as Threshold which we donated 50,000 to in We support and sponsor local universities allowing them to collaborate with our experienced team and give them guidance and tours where possible. We are corporate members of the Lion s Club. We value our surrounding communities and aim to provide investment to help local businesses and charities, find out more in our local community involvement policy. Ethical policy In 2016 Techrete was awarded a Very Good rating under BES 6001 Responsible Sourcing of Construction Products. Techrete abides by its ethical policy statement, work safe policy statement, smoke free policy statement, sustainability policy, environmental and energy policy, water usage policy, transport policy, green travel policy and corporate social responsibility policy. Supply Chain Management Through our Quality Management System, certified to ISO 9001, we have a documented system for our purchasing process and approval of suppliers. Techrete also maintain a list of suppliers, ensuring they have the necessary controls, processes and management systems in place to allow for the identification and traceability of supplier materials. We minimize the impact of the transportation of our products by maximizing the load to capacity ratio for each delivery, reducing the number of trucks on the road. We ensure that our sourcing operations comply with our business codes of conduct and legal requirements through our integrated environmental and energy management systems. Quality management Techrete s quality management system records all training and qualifications received by our staff and subcontractors and identifies opportunities for further training. Achieving these qualifications ensures that our staff meet the highest quality standards when manufacturing our products. We aim to produce the highest quality products and have put in place a quality policy to meet when designing, manufacturing and erecting our panels.

4 Techrete s Sustainable Production The manufacture of precast concrete cladding takes place in Techrete s safe, efficient and well-managed factories. The protected environment in these facilities not only ensures high quality products; it also makes environmental protection and sustainable manufacture easier to achieve. Innovative approaches to conserve resources, prevent pollution and enhance safety Materials and waste management The way in which precast cladding is produced is inherently resource-efficient. The process relies mainly on local supply chains. Factory scheduling is highly efficient with repetition being key to achieving the greatest economies Techrete has expertise in managing and conserving natural resources, taking great care to design concrete mixes so that cements, aggregates and other materials are combined to produce high quality products. In addition, it seeks to reduce primary resource extraction, minimize waste and production energy by using: Cement replacement materials such as ground granulated blast furnace slag, fly ash and silica, which are by-products from other industries and would otherwise go to waste. Self-compacting concrete which removes the need for vibration and saves energy, reduces noise, prevents hand arm vibration syndrome (HAVS) and hearing loss in workers, using fewer primary aggregates. Locally quarried stone saving on transport emissions and fuel. 100% recycled steal and stone saving a lot on energy and reducing waste. Steel can be cut and bent to shape on demand in the factory and is all purchased from CARES-approved suppliers. Recycled water from finishing process which reduces the burden on boreholes and main water supplies. Both factories capture rainwater on the roof. We capture rainwater on the roof and store it in our lagoon. This is then used in the polishing process and washdowns. Minimal use of hardwoods with timber sourced from forestry stewardship council (FSC) approved suppliers for moulds. Reducing mould and tables, steel moulds and well-designed timber moulds can be reused many times. Recycling and waste minimization initiatives, segregation of waste happens at source, additionally panels are delivered without packaging. Efficient curing and finishing techniques, Techrete use closed curing chambers and sealed chambers for grit blasting, producing virtually no waste as grit is recaptured and reused.

5 Waste Reduction Techrete continually aims to reduce its landfill waste. In our Balbriggan factory there has been a significant drop in waste in 2017/2018 due to our newly formed partnership with companies that help us recycle product.

6 Energy Consumption Techrete has particularly focused on energy conservation and sustainability for several years. After appointing an energy management team in 2010 Techrete received an IS EN certification and in 2012, transitioned to the international standard ISO Techrete continue to introduce numerous energy management actions across all facilities. Staff awareness and induction programmes have been implemented to instil the importance of viewing sustainability as integral to all Techrete operations. In addition to weekly reports to senior management, KPI s are posted on staff noticeboards. Online sub metres show us energy consumption in real time, allowing us to respond to any issues as soon as they arise. Techrete have worked with the sustainable energy authority of Ireland, the carbon trust UK and energy consultants to carry out Product Life Cycle Assessments and identify all areas of operation that could be improved on from an energy efficiency point of view. The initiatives implemented reduced overall energy consumption per unit manufactured, by more than 13% in three years. In 2008 our Dublin office moved to a new location that allowed us to design a new factory with energy efficiency in mind. In Brigg we faced a different challenge as we were retrofitting an existing building, however, that has not stopped us from reducing energy consumption.

7 Co2 Emissions In addition to reducing energy consumption, Techrete has been investigating green energy sources to replace existing ones. We now source all our Electricity from 100% renewable sources. In our Dublin office, geothermal energy is used for heating and cooling through an exposed flooring system using cast iron piping. Exposed concrete surfaces maximise the thermal capacity of the office. Passive ventilation in lieu of air conditioning and PIR-controlled lighting help to reduce energy consumption. The insulated concrete panels used in the construction of the facility were designed with large thermal mass within the insulated portion of the building. As the concrete absorbs energy when surrounding temperatures are higher than the mass and gives back energy when surroundings are cooler, this flattens out daily functions in temperature, improving comfort levels and reducing energy requirements. Statistics from the Sustainable Energy Authority of Ireland and The Carbon Trust show that energy consumption in our office is some 70% below levels required by a typical office. The panels used in the construction of our offices were designed and manufactured by Techrete.

8 Water Consumption Techrete consumes a large amount of water in the manufacture of precast panels. The water is used not just in mixing concrete but also in acid etching panels. Water and waste concrete produced by our Balbriggan factory are passed through our modern recycling plant where waste water is separated from aggregates, treated and reused. The separated aggregates can be recycled and used as hardcore. Techrete s Balbriggan plant was designed and built as to maximise our ability to recycle and reuse water. All rainwater is drained from hard surfaces to our 2,500 m3 attenuation pond where it can be treated and used in our manufacturing process. We aim to use up to 65% of water that is recycled from this system, however, in 2018 we did not hit this target since the unusually hot weather in the summer dried up our lagoon forcing us to use water from the mains. Up until 2017/2018 our Brigg factory was not able to recycle water, with sustainability in mind it was one of Techrete s focuses to change this. When the Brigg extension was built, a bore hole was dug. The bore hole is connected to the attenuation pond and can top up the attenuation pond when required, which will allow us to start using recycling water in our U.K factory soon.

9 Energy Management Techrete has won the Sustainable Energy Authority of Ireland (SEAI) SME Energy Management Award in This award highlights how Techrete has embraced energy management and have incorporated it in the day to day running of its business. Techrete has involved employees in supporting effective energy efficiency initiatives. It also recognizes the reductions in energy usage and Co2 emissions achieved. Green Awards Techrete has been presented with the prestigious Green SME award on many occasions. Including being presented with the green manufacturer of the year in The green awards, reward companies that strive to help prevent climate change by reducing waste, carbon emissions and water consumption. For more information on Techrete s Green SME awards visit our website. Transport Policy Techrete uses just-in-time deliveries and GPS tracking on trailers to avoid traffic congestion. With deliveries booked in at the construction site and communication between the wagon driver and Techrete installation teams, this allows the wagon to be met and offloaded as it arrives on site. We have invested in new tech trailers, which allow the transport of larger panels and reduce the number of loads needed for a job. These larger panels also reduce the number of crane lifts needed, speed up the erection process and minimize traffic disturbances in the local area. Furthermore, weekly monitoring of load-to-capacity statistics for each job allows us to set traffic reduction targets.

10 Safe Simple Energy Efficient Less Expensive Installation Most of a buildings energy is consumed during operation, as a result energy used during construction is easily overlooked. Additionally, with energy prices rising, there is growing pressure to ensure sustainability in onsite operations. Precast concrete panels can be produced with all the necessary elements of wall construction included. For example, internal and external finishes, insulation and fully glazed windows can all be fitted in Techrete s factory. This is a highly cost-efficient way of facing a building as the only thing finished on site is the jointing and sealing. All of this benefits the contractor in developing and implementing a site waste management plan. The installation process is very energy efficient, with precast cladding: Crane time and number of lifts are optimized Site cranes are used with no need to bring in additional equipment No need to double handle the panels No wet trades Little energy is needed, and no power tools are needed Small teams of specialist erection workers travel to the site together, saving on fuel emissions.

11 Sustainable Performance Durability So as that buildings can offer outstanding performance standards in use and even outlast their intended service life, they should be long lasting and adaptable to change. In this regard, our precast panels offer several benefits: Extending the footprint: Our concrete panels can be removed safely and reinstalled after works. This reduces waste from refurbishment projects. Robust and easy maintenance: The high-quality surface finishes achieved in our factories result in panels that are strong and easy to maintain. Reduction in maintenance: Typically, the panels have 50+ years design life, reducing maintenance costs and inconvenience for the owner. Resistant to elements: The strength precast concrete holds for years after its cast means that panels hold up against rain, debris and in some cases, blasts and chemical attack. Fire resistant: Precast concrete panels do not catch fire, burn, melt or drop molten particles. This can prevent the spread of fire and sometimes only minor repairs are needed. Whole life performance The use of precast concrete cladding in a building contributes to its thermal mass, which helps to even out daily and seasonal temperature swings, making indoor spaces more comfortable without having to resort to air-conditioning. Additionally, in countries with a lengthy winter season, such as the U.K and Ireland, certain levels of insulation must also be provided in the building to ensure that heat is not lost through the façade. There is no problem combining precast concrete cladding with insulation product either in the factory or on site. Efficient insulation Precast concrete insulated sandwich cladding panels offer a very efficient and practical solution, achieving a U value of 0.25 w/m2k or better. Insulation sits within two precast concrete layers; the external leaf provides protection against the elements and the internal layer provides thermal mass in the right place, i.e facing internal heat sources such as people and computers. The vulnerable insulation layer is thus protected effectively, and the building envelope is doing all that can be asked of it by moderating extremes, whether these arise from cold winter temperatures or internal heat gains. The occupants remain comfortable and the building owner saves energy and money. What s more, precast concrete is inert, so it doesn t give off any gases, toxic compounds or volatile organic compounds in use.

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