EcoCanopy

Product Guide
Contents
01 02 03 04 05 06 07

Introduction Modular Flexibility Rules and Configurations Procurement Route and Deployment A Note on Costs Design Standards Outline Specifications

04 06 08 10 11 12 13

Precedents 08 09 10 11 12 Egerton Drama & Teaching Block Graveley Primary School Little Dragons Nursery Egerton Rothesay SEN Facility Environmental Response 14 16 18 20 22

Amy MacSween [email protected]

Offsite Construction Magazine Awards 2009 winner for Best use of timber

01 Introduction
EcoCanopy is a high-quality pre-engineered building system based on a series of standard components such as roof cassettes and wall panels, windows and floors.

EcoCanopy
The factory environment in which EcoCanopy is produced ensures a high level of quality, efficiency and cost-certainty.
Images Below: the southeast facing facade and entrance of a new SEN Primary School Facility at Egerton Rothesay School. Previous page: a typical EcoCanopy classroom with two roof lights, at Graveley Primary School.

EcoCanopy is unique EcoCanopy creates robust, permanent buildings with a lifespan comparable to conventionally built buildings. We use design discipline and manufacturing efficiencies to drive down cost. Historically, most clients have been faced with two choices when requiring small to medium sized building solutions: costly traditional construction methods, or low-quality prefabricated temporary solutions. EcoCanopy offers a unique third way, that is, a cost-effective permanent building solution that utilises the best of Modern Methods of Construction (MMC) to provide high-value buildings.

Genesis EcoCanopy was developed in response to the clear requirement for cost-effective, time-sensitive, environmentally-friendly small building solutions for local authority Capital Programmes. EcoCanopy was also developed to deliver Sure Start Children Centres for local authorities. This rollout met tight delivery and cost targets, and the success of the programme led EcoCanopy to be available as a building solution to other clients requiring similar, or much larger, scale buildings.

Delivery To date over 25 EcoCanopy projects have been completed, including a 500m2 two-storey school building. EcoCanopy has expanded its offer into larger education projects, as well as retail, commercial and public applications. Maintenance requirements are simple and easily carried out by site staff (such as caretakers) or local contractors. An aftercare service is also available from EcoCanopy.

How to use this document This document includes illustrations of possible arrangements of EcoCanopy buildings, from single storey to two storey school buildings. The cost-certainty of each element ensures that very accurate value-engineering decisions can be taken at any stage, enabling accurate project management and expectation management.

02 Modular Flexibility
Intelligent standardised modules can be configured to suit site-specific internal and external space requirements
3.6m wide Wall

EcoCanopy can provide standalone buildings or extensions to existing buildings

2.4m wide Wall 1.2m wide Wall Corner Post Internal Column

EcoCanopy is assembled on site like flat-pack furniture resulting in a process that saves the client both time and money
2 Storey 7.2m High Wall

Fixed Window

Opening Window

External Door

Standard Infill (550mm)

Stretch Infill (up to 1200mm)

Strip Window

Roof Light Canopy

External Canopy

Standalone Roof Light

Standard Roof Canopy

Flexibility Windows and doors can be arranged in a completely flexible way to precisely address the design brief. Clear spans and heights can be altered to deliver large spaces, such as dining halls, indoor PE halls (e.g. badminton courts), drama spaces, large music rooms, etc. EcoCanopy is based on a plan module of 4m x 4m, with a flexible infill grid and smaller 1.2m or 2.4m x 4m module integral to the system. The flexibility of the component based system enables any plan arrangement and area

to be achieved. The EcoCanopy facade system is arranged in a series of 1.2m modules. These modules can be arranged as solid walls, opening or fixed windows, 1000mm clear-opening single doors, leaf and half doors or double doors and at design stage can be interchanged to suit very specific site views, access requirements, and solar orientation. Internal walls are arranged independently of the plan module, allowing compete internal design freedom. EcoCanopy can be dismantled and relocated or extended by adding and re-using components.

Pre-cast slab

Floor Infill

Portal Frame (offering 8m clear spans)

Any combination of standardised components and building modules can be used to achieve the desired scheme
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03 Rules and Configurations

Any combination of standard and non-standard building modules can be used to create the desired spatial grid
Standard Infill (550mm)

Single storey and two storey wall panel modules can use any combination of EcoCanopy window and door components

Standard Infill (550mm)

Roof Light Canopy

1. Standard infill grid

Standard Canopy Roof Light Canopies and Standard Roof Canopies can be arranged to form any building pattern on a 4150mm grid using standard infill panels.

Example 1: A single storey wall module incorporating an external door, an opening window and timber cladding.

Example 2: A single storey wall module incorporating 3 fixed windows creating a fully glazed wall.

Stretch Infill (up to 1200mm)

Stretch Infill (up to 1200mm)

Standard Canopy

2. Non-standard infill grid

Roof Light Canopies and Standard Roof Canopies can be arranged to form any building pattern up to a 4800mm grid using stretch infill panels.

Stretch Infill (up to 1200mm) Roof Light Canopy

Standard Infill (550mm)

Stretch Infill (up to 1200mm)

Standard Infill (550mm)

Roof Light Canopy

3. Standard and non-standard grid

Roof Light Canopies and Standard Roof Canopies can be also arranged to form any building pattern using a combination of standard and stretch infill panels.

Stretch Infill (up to 1200mm)

Example 3: A two storey wall module incorporating a fixed window, an opening window, 2 external doors and three strip windows. The first floor door typically opens onto a fire escape stair landing.
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Example 4: A two storey wall module incorporating 3 fixed windows, an opening window and an external door. A two storey wall can be used to create a double height space or separate floors.
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04 Procurement Route and Deployment

Procurement route EcoCanopy demonstrates best value to clients by offering high-standard performance specifications and a fixed price, measured against benchmark prices for traditional-build solutions at the same performance specification. Such an approach saves the client the time and cost of a conventional tender process. This information is provided very early in the process, to enable simple feasibility studies and cost-checking. Should a conventional competitive tender process be required, EcoCanopy offers full cost transparency of all the individual components which form the project cost. This includes all provisional sums for groundworks, service connections, drainage and landscaping, as well as detailed subcontractor preliminary costs. EcoCanopy has successfully delivered for private clients, local authorities and independent schools. You are warmly invited to visit any number of completed projects and our manufacturing facility to gain a clearer understanding of the EcoCanopy offer. Deployment Factory-fabrication allows EcoCanopy to reduce site time to a minimum. This offers essential value in four areas: 1. 2. Health and Safety: by manufacturing the product in a controlled environment, site-related work is minimised, and hence risks to safety are substantially reduced. Disruption to Clients: the short programmes and reduced heavy vehicle deliveries means that EcoCanopy can be delivered on live sites with minimum disruption to users. For example, on a typical school site the heavy deliveries and erection can be arranged for a half-term week, and the subsequent low-impact work can continue with minimum noise, dust and visual impact on pupils, teachers and parents. Programme Certainty: EcoCanopys short programmes means that site-related hidden costs are kept to a minimum, and the factory production removes most programme-related risks. Efficient Preconstruction Period: On all projects, the preconstruction time and costs can represent a substantial portion of the budget. As a developed system, EcoCanopy feasibility, cost and construction information can be quickly produced, reducing fee costs and time and offering very accurate budget and specification information. This is particularly useful for contract processes such as value engineering.
42 weeks

05 A Note on Costs
The following information lists what is included and excluded from EcoCanopy
EcoCanopy costs include the following: Full manufacture and installation of EcoCanopy in accordance with employers requirements including a fully finished, serviced, fitted-out building. Delivery to site. Footings to 750mm depth. Detail design fees (RIBA stage E L) for a combined service, including architectural, structural, and MEP design.

*EcoCanopy costs exclude the following: Whole life costs EcoCanopys enhanced environmental performance results in lower energy-in-use costs when compared to traditional solutions. Care is taken to ensure simple operation of servicing devices, to ensure that end users derive maximum cost and performance benefits from EcoCanopy. Maintenance and insurance costs match standards for traditionally constructed buildings.
Traditional Construction Costs vs EcoCanopy Single and Two Storey Costs / m
Traditional Construction 2500 EcoCanopy Single Storey EcoCanopy Two Storey

Design fees up to RIBA stage D Alterations to the existing building Landscape works Services runs and connections Alterations to the car park Onsite renewables requirements beyond AD Part L 2010 compliance FF&E incl blinds & loose fire fighting equipment Statutory fees for Planning and Building Control BMS / PA system TV/CCTV installations Lightning protection VAT * Please Note: All items can be provided if required.

3. 4.

Traditional Construction Programme vs EcoCanopy

27 weeks 22 weeks 16 weeks 15 weeks 12 weeks 8 weeks 4 weeks Traditional Procurement EcoCanopy Procurement

On Site Construction Period Factory Manufacture Period Planning Period Cost / m (av. price ranges)

2100 1900 1500 1200 1000

Design Period Traditional Construction

Images: A wall module being lifted (left) and a timber element being machined to size (right) at the Andover manufacturing facility.

EcoCanopy Single Storey

EcoCanopy Two Storey

Image: a view of the Andover manufacturing facility.

Chart 1.1: Traditional Construction Programme vs EcoCanopy

Chart 1.2: Traditional construction costs vs EcoCanopy costs for single and two storey buildings ( / m)

Programme EcoCanopy reduces the construction programme and disruption on site when compared to traditionally constructed buildings. Site work disruption is reduced from months to days. As the EcoCanopy components are delivered and erected fully clad and internally finished, it also offers programme savings compared to other volumetric/system build solutions. Chart 1.1 compares the construction programmes for a 180m building. The reduced site disruption is beneficial to all projects, and is particularly relevant when working within existing sites such as schools and healthcare facilities where construction periods are limited.

Affordability EcoCanopy is more affordable than traditionally constructed buildings, yet offers higher quality construction, materials and finish. It is also more affordable than volumetric/system build solutions that offer a lower quality environment. EcoCanopy uses design discipline and manufacturing economy to drive down costs and increase quality. Chart 1.2 gives comparative costs between EcoCanopy and traditionally constructed buildings. The affordability of EcoCanopy does not result in a reduction in quality of building, services or materials used. Savings are made due to the sophisticated and efficient manufacturing process, reduction in material wastage, reduction in labour content, reduction in transportation/delivery costs and reduction in site preliminaries. All projects offer site-specific costs that are applicable to all methods of construction.
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06 Design Standards
Educational Experience

EcoCanopy creates inspirational internal spaces with a very high quality of finish. Flexibility, accessibility and security are built into the system.

07 Outline Specifications
The following specification is delivered as a minimum: External finish: cedar cladding, rendered panels, aluminium cladding and brick slips; costs will vary slightly. EcoCanopy timber originates from a FSC certified source. Internal wall finish: tape and jointed, or plastered with an eggshell painted finish. Internal ceiling height: 2.7metres (which can be increased in 400mm increments). Roof: 1-2 degree GRP or single ply membrane roof with ballast. Glazing: timber double-glazed windows with stainless steel window furniture. Floors: concrete waffle slab with ply decking, insulation and floor finish. Ceiling: fire rated plasterboard or acoustic plasterboard panels between or below the roof structure. External Doors: solid timber or glazed timber framed doors. Internal Doors and ironmongery: lockable painted timber doors with anti-finger traps, kick plates and vision panels where required (FR30min where appropriate). Windows: timber double-glazed windows / 4mm toughened 16mm argon filled cavity 4mm toughened. EcoCanopy uses low E glass. Flooring: carpet tile, vinyl or timber as required. Safety flooring and barrier matting is also available. Splashbacks: 150mm x 150mm plain white ceramic wall tiles with white grout. Joinery: all skirtings, frames, cills and architraves as required. Sanitaryware: Armitage bathroom range or similar products with mixer taps, temperature controlled as required. Heating: various systems are available to meet end user needs and connect to existing services on site. Small power as required: typically 10 double sockets and 10 data points per classroom, 5/3 per office, 10/10 for multipurpose facilities. Lighting: high efficiency recessed, surface mounted and/or suspended lighting, emergency and moistureresistant lighting where required. Fire detection: smoke/ heat detectors as required by the Building Regulations. Hot water: supplied in line with services strategy. Hot water temperature controlled where required.

In every project, EcoCanopy seeks to capitalise on the inherent educational value of the construction process. EcoCanopy offers several onsite activities for staff, parents and pupils, as well as factory visits for groups of up to twenty-five at a time. Design Standards Design Life Appearance The use of timber cedar cladding as main building material provides not only a pleasant, warm atmosphere for the users, but it blends into the natural surrounding. The cedar board is arranged horizontally, with horizontal aluminium trims every 400mm ensuring consistent weathering. The roof structure can be exposed internally to create an interesting, inspirational learning environment as shown in the internal images. Good levels of daylight will enter the building through the roof lights, which are themselves surmounted by triangular protective hoods that are open to light from the north, which peak at 1.25m above the lightly sloping, GRP roof. They form a distinctive feature of the building and their function is to protect the roof lights against direct sunlight from the south. Timber columns are expressed externally. A continuous timber fascia caps the building off. A 400mm dark-grey Eternit board is installed at the bottom of each EcoCanopy wall panel. Double-glazed windows in timber frames match the timber doors. Both are typically painted white/grey but can be painted any colour to suit requirements. A minimum structural design life of 60 years is achieved A minimum faade design life of 25 years is achieved A minimum roof design life of 15 years is achieved EcoCanopy fully complies with the suite of Building Regulations Approved Documents and ancillary British Standards Acoustic standards meet BB93 Fire performance standards meet BB100 Ventilation standards meet BB101

EcoCanopy is fully building-regulations compliant. The low visual impact, low environmental impact and short construction time results in a planning-friendly offer. EcoCanopy has also been granted planning permission in Green Belt and Conservation Areas.

Images (from left to right): EcoCanopy material and product options: 1. Cedar and glass cladding 2. PV roof array and sun shades 3. Standard cedar cladding 4. Strip window glazing 5. Alucobond cladding (various colours available) 6. Rendered external wall finish

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08 Egerton Drama andTeaching block

Brief: Drama and Teaching Block Client: Egerton Rothesay Independent School Programme: Completed October 2010

GROUND FLOOR PLAN 223m2 Gross Internal Floor Area (GIFA) 252m2 Gross External Area (GEA)

FIRST FLOOR PLAN 223m2 Gross Internal Floor Area (GIFA) 252m2 Gross External Area (GEA)
Top left: external cladding Top right: internal star Bottom left: external view Bottom right: during construction

EcoCanopy
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5m

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09 Graveley Primary School

Brief: Primary School Extension to an existing building Client: Hertfordshire County Council Programme: 10 weeks, completed 2009

GROUND FLOOR PLAN 228m2 Gross Internal Floor Area (GIFA) 245m2 Gross External Area (GEA)
1 2 3 4 5m

EcoCanopy
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Left: EcoCanopy exterior Right: EcoCanopy (foreground) connected to the existing building (background)

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10 Little Dragons Nursery

Brief: Sure Start Nursery, Amersham. Client: Buckinghamshire County Council Programme: 9 weeks, completed October 2010

PLAN 244m2 Gross Internal Floor Area (GIFA) 265m2 Gross External Area (GEA)
1 2 3 4 5m

Above: a typical EcoCanopy floor slab being craned into position

Top: internal play space Bottom: external covered play area

EcoCanopy
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11 Egerton Rothesay SEN Facility

Brief: SEN Primary School Facility Client: Egerton Rothesay Independent School Programme: 14 weeks, completed 2008

PLAN 240m2 Gross Internal Floor Area (GIFA) 260m2 Gross External Area (GEA)
1 2 3 4 5m

Top: entrance area Bottom: external view

EcoCanopy
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12 Environmental Response
Environmental and Sustainability Considerations Energy Heating and Ventilation Rainwater Disposal

EcoCanopy projects have achieved a BREEAM Excellent rating

The cladding and building frame are made from timber, which substantially reduces material embedded energy. EcoCanopy timber originates from a FSC source. Not only is the timber a grown product from managed forests, but it is also easy to use, naturally insulating and warm to touch. No tropical hardwoods are used. The components have been designed to be reusable, and the whole building could be dismantled, relocated, reused or recycled and adapted. The glass fibre reinforced (GRP) plastic roof is also a sustainable feature which is more environmentally friendly than alternative membrane covered flat roofs. GRP is very robust, has no joints and requires less maintenance than other roofing systems. In addition, the system is enabled for the future installation of micro-renewables that can make the EcoCanopy zero-carbon by operation.

The EcoCanopy building system has low carbon emissions due to its high fabric performance, low infiltration rate and use of appropriate technology (such as heat recovery ventilation). Solar control and cross-ventilation improves the passive performance of the building. Active and passive environmental features are suitable to be used, such as living and biodiverse roofs and micro-renewables. The factory-based manufacturing process using low-embodied energy products (timber) results in a low-energy manufacturing process. The building envelope complies with Approved Document Part L 2010 maximum U-values and air permeability rates. Part L 2010 compliance is demonstrated using BRUKL calculations, or a full dynamic simulation method as detailed in CIBSE AM31. Overheating is controlled in line with BB101 requirements.

A number of heating systems are available, including underfloor heating, VRV units and radiator panels. A system of manually controlled opening windows ensures that the EcoCanopy spaces are adequately naturally ventilated. The natural ventilation openings are designed in order to meet the requirements of AD L2 Prevention of overheating along with the requirements of Building Bulletin 101. Electrically powered extract fans are provided in kitchen and WC areas. These fans are powered and controlled from the local lighting circuit. Ventilation via heat recovery units are also available.

Rainwater from the roof of the EcoCanopy building typically discharges via down pipes on two sides of the building. In most installations, rainwater discharges into a concrete ring soakaway chamber designed in accordance with BRE digest 365 to accept the anticipated rainwater inflow volume. The soakaway is fitted with heavy duty cast iron access cover and frame suitable for siting in the soft landscape surrounding the building.

Air, Water, Noise and Light Waste Health Energy in use BREEAM ratings Fabric Performance Wall: 0.2 w/m2/K Roof: 0.17 w/m2/K Floor: 0.19 w/m2/K Windows and Doors: 1.5 w/m2/K Rooflights: 1.5 w/m2/K Air Infiltration rate: 5 - 7 m3/hr/m2 The low material-embodied energy and factory fabrication of EcoCanopy ensures that EcoCanopy inherently achieves a BREEAM Very Good rating, independently of site conditions and fuel source. With small cost-effective interventions and attention to site-specific and management procedures, a BREEAM Excellent rating is readily achievable with EcoCanopy. The in-house design team can provide a project-specific energy assessment as part of the design process. The baseline performance of EcoCanopy makes zero-carbon a realistic and achievable target for EcoCanopy projects. EcoCanopy has been designed to integrate heat recovery systems. No unsafe building materials are used with the proposed building (e.g. asbestos, organochlorides). No COSSH items or processes are required in the construction process. No hazardous materials will be stored within the building. Timber is inherently less toxic than metal or composite cladding systems. The manufacturing process of the EcoCanopy building system results in minimal material wastage. Factory conditions allow for extensive waste management. EcoCanopy have collaborated with WRAP to reduce waste to a total of 3% of materials used; of this 3% waste, 90% is recycled and 10% is sent to landfill. The amount of site waste is minimised through the application of a Waste Action Plan. The use of over 90% off-site manufactured components reduces site-work disruptions from months to weeks. The conditions of production are controlled; air pollution and dust from construction are reduced to virtually zero. Vehicle emissions are reduced when compared to conventional construction. Due to the good amount of glazing and roof lights the level of natural daylight is excellent and therefore this results in low artificial lighting during the day. External lighting is cast downwards to reduce light pollution. No inverters or other noise-generating electrical installations are typically installed. Offsite manufacture means that wet trades are almost entirely removed from the process, and as result, site-related water use and runoff is reduced.

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