Projects

FULL PROJECT DETAILS

Blitzsteel led this design and build project as principal contractor, using modern methods of construction to maximise programme efficiencies. We developed a solution that not only upheld Mint Hotel’s ambition to be an innovator in the hotel industry, but fulfilled our ambition to reach above and beyond client expectation.

RISING ABOVE INNER CITY CONSTRAINTS

This project gave us an opportunity to add to the humming, energetic atmosphere in the heart of London. While the building architecture had to sit comfortably within its surroundings, the roof offered significant design freedom. We let our expertise flow to create the Skylounge (a rooftop box at a slightly different angle) to capture views of the Thames and Tower Bridge.

STRIKING INNOVATION

We have created the largest ‘living’ wall in Europe, adding to the hotel’s visible and sustainable appeal. We used 185,000 plants during its installation, creating a green blanket that spreads vertically within the atrium and two upper floors externally. The installation comprised individual modules, each featuring 45 planting cells with a water irrigation system. It not only reduces heat loss and internal cooling, but also improves air quality and carbon fixing, reduces noise and provides a habitat for wildlife.

REAPING THE BENEFITS OF FORWARD THINKING

We kept energy consumption at the forefront of all planning, and used this passion to develop a substructure design initiative that enabled the new proposed electrical substation to be installed within the basement and energised nine months ahead of programme. This resulted in the site generator being switched off in the early stages of construction, allowing us to connect to the power grid at a much earlier stage than the scheme originally anticipated. Not only did this save an abundant amount of energy, but with one swift move we were able to offer the client considerable cost savings.

DESIGNING IN SUSTAINABLE SOLUTIONS FROM THE OUTSET

We installed photovoltaic (solar) panels, ground source heat pumps, passive and active low energy systems, and a combined heat and power unit to ensure 10% of the hotel’s energy is renewable. In addition to the positive impact of the ‘living’ wall, these combined measures reduced carbon emissions by over 30% and surpassed the BREEAM Excellent standard by 40% for overall energy consumption per bedroom. This positive outcome adds testament to our ability to ‘find a better way’ using value engineering – ultimately exceeding planning requirements, and pleasantly surprising the client.

A VALUABLE ALTERNATIVE SOLUTION

Blitzsteel managed and oversaw the entire construction process, using innovative techniques such as Design for Manufacture and Assembly (DfMA), where sections of the hotel were built off site in our in-house manufacturing facility and delivered to site systematically. This approach gave us the opportunity to apply innovative solutions to complex challenges throughout the design, manufacturing and construction phases.

At the beginning of the project, three key areas were identified as suitable for DfMA: the concrete frame, the external envelope and the guest bathrooms. Although originally designed as an in situ concrete construction, we proposed an alternative solution using twin wall / lattice floor slabs with structural topping. We also developed a bespoke solution for the twin wall to overcome spatial constraints. Once manufactured, the precast concrete sections were delivered to site and hoisted into place. Deliveries were carefully scheduled so that they arrived only when required – this ‘just in time’ delivery solution ensured efficiency and reduced congestion.

When compared to conventional in situ techniques, our approach benefited health & safety the environment and shortened the construction programme by ten weeks.

AWARDS

• Future Design Award for Sustainability, European Hotel Design Awards
• Shortlisted for Best New Build Hotel, European Hotel Design Awards
• Finalist for Construction Manager of the Year: Alan Blewett MCIOB
• British Association of Landscape Industries Principal Award Winner

FULL PROJECT DETAILS

With the world watching, Blitzsteel – as part of the ODA’s delivery partner CLM – was tasked with delivering one of the most complex feats of programme management ever undertaken. The result was the transformation of 670 acres of contaminated wasteland in Stratford into a world-class venue – delivered over the line on time and to budget. The project set new industry benchmarks for safety, quality and sustainability. We provided programme and logistics management, first-tier delivery of construction and operational services, carrying out extensive decommissioning to deliver the facilities in both Olympic and legacy modes.

THE HOME STRAIGHT

Coordinating a multitude of stakeholders and contractors, 3,000 supply chain members and over 46,000 people over the project’s lifetime required a clear vision and strategic methodology. Failure to meet the ODA’s deadline and rigorous construction and infrastructure milestones was not an option.

We championed a collaborative culture and established clear organisational protocols, governance and reporting to offer a fast-track solution that would ensure timely and successful delivery of this politically charged venture.

COMMITTED STAKEHOLDER ENGAGEMENT

Excellent diplomatic skills maintained relations with the Park’s neighbours within the five host boroughs as well as with Network Rail, Crossrail, Westfield shopping centre and the major utility companies. We engaged with the community by establishing a 24/7 hotline and holding weekly consultations. We responded to feedback, for example, by using bored piling instead of pile driving to reduce noise. Two logistics centres coordinated four deliveries per minute, further minimising traffic, disruption and
CO2 emissions.

A LEARNING LEGACY

As part of the legacy, we created a transparent trail of lessons learned. This embedded health and safety, sustainability, and employment and skills targets, and it focused our leadership to identify areas for improvement to achieve excellent results here and elsewhere.

AWARDS

• RoSPA Diamond Jubilee Award
• Considerate Constructors Scheme Gold (twice)

FULL PROJECT DETAILS

Blitzsteel were appointed principal contractor delivering a modern, flexible space to optimise research opportunities and strengthen the Department’s international profile. We provided accommodation for 400 students, researchers and staff, with metal-free ‘clean’ laboratories, lecture theatres, conference rooms, offices and a library.

This multi-award winning geological research building was a hot-bed of innovation and one of the first projects to optimise delivery through our Design for Manufacture and Assembly (DfMA) process. It was designed to provide an open and interactive environment that will encourage scientists to share ideas. One wing houses state-of-the-art laboratories, the other offices and common rooms.

Energy saving
Laboratories are separated from the offices so that the less highly serviced spaces can be naturally ventilated. In summer the passive design uses the thermal mass of the building for cooling and solar gain is reduced through user-controlled external blinds. We drilled 63 boreholes – 65m deep – to install ground source heating and cooling technologies that provide up to 35% of the building’s energy. A post-tensioned slab system reduced the volume of concrete by 10% and GGBS cement replacement was selected for the structural elements. We precast the columns, stairs and cladding off site to minimise waste and improve on programme delivery times.

Metal-free clean laboratories
The building’s clean geochemistry laboratories were a considerable challenge; having to be completely metal-free to avoid interfering with the intended research. Designing and delivering them required the designers, end users and specialists to work closely to agree a suitable construction solution.

Facade design
We collaborated with the Professor of Stratigraphy to select the most durable stone – the final design having geometric bands of Clipsham, Jura and Purbeck that create a dramatic ‘narrative wall’ to frame the entrance and advertise the nature of the work within.

Awards

• Considerate Constructors Scheme Gold (twice)
• CIOB Construction Manager of the Year

FULL PROJECT DETAILS

Francis Crick discovered the helix structure of DNA; this building, too, will change the world of science. Innovation, technology and collaboration will reign supreme – the very values we have advocated to deliver the aspirations of our client.

We probably undertook as much scientific research about the building as will take place within it. We modelled/analysed numerous scenarios associated with the incredibly stringent vibration criteria; the spatial and electromagnetic compatibility of MEP and research equipment; and the requirements for a system to recirculate a vast 430m3 /s of fresh air.

REDEFINING ENGINEERING EXCELLENCE

Our modular and precast solutions delivered programme and logistics efficiencies and enabled us to overcome the complexities of constructing a highly sophisticated building within a ‘landlocked’ site. Manufactured in our specialist facility at a rate of 150 units a week, our MEP modules range from horizontal distribution and software-loaded units through to those that we custom-built to accommodate the supply and extraction ducts that feed into highly sophisticated particulate arrestance filters. We also manufactured more than 2,000 sections of pipework and over 5,000 precast components (including the world’s largest offsite manufactured stainless-steel reinforced plunge columns), all of which we delivered ‘just in time’.

A MODEL APPROACH

Our award-winning digital engineering team ‘constructed’ the institute several times and rehearsed every major plant installation in the digital model, from which we extracted images to develop visual method statements that communicated safe sequences for complex tasks. This was critical when we installed larger items such as a 40-tonne boiler, which had only 50mm clearance.

OPTIMISED ENVIRONMENTAL PERFORMANCE

Thanks to a wealth of environmental features, this will be the first ever laboratory to meet 2010 energy regulations. These include innovative glazing and shading; high-efficiency plant; and lighting control and ventilation systems with variable-volume flow.

FULL PROJECT DETAILS

DESIGN AND ENGINEERING

The structure’s distinct asymmetrical shape – a response to planning requirements to maintain views of St Paul’s Cathedral – meant settlement both in the foundations and through compression of its elements would be irregular. The solution was to design the building to be erected slightly off the vertical so that it would settle in its correct form. This made the construction process exceptionally challenging. Working with tall building expert, Bill Baker of Skidmore, Owings & Merrill, Blitzsteel came up with an innovative alternative. Now, when the building reaches the 19th floor, steel along the sloping face will be tensioned to pull the structure back to the vertical. This process will be repeated every seven storeys.

AN ICONIC BUILDING

The development’s tapering shape, which when viewed from the west appears to ‘lean away’ from St Paul’s Cathedral, delivers varied sizes of floor plates, all offering spectacular views over London. Practical completion of the shell and core is scheduled for mid-2014. Exceptional engineering skills were necessary therefore, to develop a construction methodology that enabled the building to stay upright – with tolerances of plus or minus 20mm required on all but five of its floors.

Using multidimensional Building Information Modelling (BIM) technology, Blitzsteel devised an innovative delivery strategy that harnesses the benefits of offsite manufacturing. This ‘virtual construction’ approach allowed the client to visualise our solution in intricate detail. Critically, by integrating data from the architects and structural engineers, the team was able to achieve the early design coordination needed to meet such a challenging programme. The model also combines information from key trades to ensure the compatibility of the different packages.

LOGISTICS AND DFMA

The intense public interest in the development leaves no room for logistical error. Its high-profile location – characterised by narrow and densely populated streets – along with the site’s remarkably tight footprint, represent considerable obstacles. To work around these constraints, much of the structure – including the cores, basement and building services – will be constructed off site. However, with components of up to 26 metres in length this creates its own challenges. Once again, the team used BIM to perfect its strategy for just-in-time assembly.

FULL PROJECT DETAILS

Built on a tight site bounded by a busy road and a railway, this stunning development is part refurbishment and part new build. It has five floors of flexible office space, ground floor retail and restaurant, five residential units, basement and service yard.

Innovative construction
A high degree of innovation and emphasis on offsite preassembly (Blitzsteel’s Design for Manufacture and Assembly approach) helped reduce risk, construction programme and overall cost, and improved quality, consistency and site safety. It also reduced the need for onsite material storage – an important consideration when working on a tight urban site.

Structural innovation
The architect and engineers collaborated with Blitzsteel companies StrongForce and Expanded Structures to design a bespoke structural system using post-tensioned slabs. Precast concrete panels that would form the ceiling soffit were made off site with a high quality finish that required no suspended ceilings. The modular roof was installed as cassettes and craned into position; it weighs a tenth of the original steel design and was considerably easier and safer to construct.

Energy efficient services
The most significant mechanical and electrical (M&E) innovation uses energy-efficient displacement ventilation instead of the usual four-pipe fan coil system for ventilation and air conditioning. Low velocity cool air enters each storey via hollow concrete columns rather than conventional central service cores, thus releasing floor space.
The exposed thermal mass provided by the structural design complements the displacement ventilation to provide effective low energy cooling – a good example of the close integration between structural, services and architectural design realised through a coherent construction strategy and sustained attention to detail.The GLA’s requirement for 10% of the building’s energy consumption to be provided from onsite renewable sources was met by the inclusion of a biomass boiler and solar thermal preheating of hot water using roof-mounted tubes.

Unitised facade
Windows 3.7m wide and 3.2m high were fabricated off site and delivered fully assembled and glazed. An ingenious sequence and system of lifting gear was used to manoeuvre and install them. This not only allowed Blitzsteel’ to dispense with the scaffolding or cherry-pickers that would normally have been needed, it also brought major health and safety benefits through reduced working at height.This exposed structural approach to the interior not only delivered the powerful architectural vision, but also reduced the risk of damage and subsequent complications with follow-on activities, and it will greatly reduce the whole-life costs of maintaining the building.

Awards

• British Precast Concrete Awards: Supreme Project
• BCO Innovation Award Shortlist

FULL PROJECT DETAILS

Blitzsteel were responsible for the design and build (including demolition and redevelopment works) of one million square feet of retail space comprising 120 flexible units over three floors, an independent cinema and rooftop restaurants.Trinity Leeds provides a ‘tapestry’ of arcades to house flagship tenants, boutique concessions and leading brands in entertainment and cuisine.

PLANET RETAIL: TWO FOR THE PRICE OF ONE

Although largely new-build, the scheme includes the refurbishment and full integration of an existing 1970s concrete-framed shopping centre. We worked on two sections simultaneously: the eastern section comprised of constructing two basement levels, three retail floors and the signature loose-fit lightweight-grid glass roof. The western section encompassed demolition works, structural alterations, facade replacement and a smaller feature roof. Both sections are linked by a two-storey bridge over one of the city’s busiest shopping thoroughfares. Internal finishes include stone flooring throughout the malls and central circulation areas, glass reinforced gypsum circular columns and an undulating ceiling. Externally, the mostly glazed facade, link bridge and landscaping combines to create a modern streetscape.

INNER-CITY LIFE CHANGING

We have introduced a Leeds-centric legacy by creating a blueprint to address the socio-economic needs of the community. This project allowed us to provide apprenticeships and jobs, raise money for charity, and engage with those suffering from debilitating conditions and/or social isolation. We have also allied with educational institutions to inspire the next generation and maximise career opportunities.