Numatic Manufacturing Facility Update

05/11/2024

Southwest

Written by

Jeff Martin
Jeff Martin

Jeff is an experienced Architect, he specialises in the design concept and planning stages of large scale commercial projects.

Our project for Numatic in Chard is developing rapidly, with significant progress to key work packages such as the external envelope, preparations to pour the concrete slab, and the external works.

The roof is nearing completion, and work has begun on the adjoining Assembly building roof, with preparations underway for the Biodiverse roof installation. The extensive steel frame is now enclosed with Kingspan Micro Rib cladding in Umber Grey, which looks striking in the autumn sunlight. The top 4 meters of cladding around the distribution building is translucent polycarbonate and as this is combined with roof lights across the 5,500m² roof, the interior is filled with natural light, reducing the need for artificial lighting.

The sprinkler tank has now been installed, ready to hold one million litres of water, while the pump house building has been erected, fully fitted with pumps and pipework to ensure facility safety. Around the site, external work is progressing steadily, including concrete retaining walls, the now hidden surface water attenuation tanks, and perimeter road construction.

Apex Media’s drone footage captures the rapid changes in development between flights, showcasing the impressive progress made by CG Fry and their subcontractors, which can be seen across this 30,000m² site.

Since this footage was shot, the subfloor piling structures have been exposed, reinforcement for the FM1 super-flat floor has been installed, and the first of eight massive concrete pours has begun. We look forward to seeing more updates from Apex Media as it is an excellent way of documenting progress throughout the development of the project.

Credits

Architect & Contract Administrators
BoonBrown

Client
Numatic

Main Contractor
CG Fry & Sons

Media Creator
Apex Media


Views on the refurbished Dorset Museum

14/08/2024

Southwest

Interviewed by

Sydney Wheeler
Sydney Wheeler

Sydney is currently studying at the University of the West of England in Bristol and is in her 2nd year of the Level 7 Architectural Apprenticeship.

We are proud to revisit the beautifully refurbished Dorset Museum & Art Gallery!

Founded in 1846, this iconic museum now features a blend of Victorian charm and modern enhancements, following a carefully planned restoration and extension. We were honoured to serve as the project architect and principal designer, working alongside contractors Acheson, guiding this transformation following the grant of planning permission through to completion.

Since reopening in May 2021, the museum showcases 250 million years of Dorset’s history, with highlights including the Fordington mosaic, a new wing, subterranean stores, and revamped spaces like the 50-seat restaurant and members’ library.

Recently, we returned to capture the voices of staff and visitors in our latest vox pop. Hear what they have to say about the revitalised museum!


Beaucroft College shortlisted for AJ Retrofit & Reuse Awards 2024

24/07/2024

Southwest

The core ambition of the project was to deliver a highly-sustainable SEN School, through the retrofit and reuse of existing buildings.

Dorset Council were keen to use Beaucroft College as an exemplary project to show case retrofitting and energy efficiency in existing buildings across Dorset and the wider region. The project was seen to be an investment in the students’ futures and the future of Wimborne as a community.

In 2021, the project was awarded Government SALIX funding to decarbonise the buildings, by decommissioning two large gas boilers and replacing them with an air source heat pump and photovoltaics.

Design

  • The former Wimborne First school buildings have been renovated to perfectly meet the needs of the SEN students.
  • Open, light-filled classrooms, with purpose-designed, integrated teaching walls, and fresh air-filled quiet rooms.
  • The old tarmac covered playground has been radically transformed into several landscaped soft play areas, with a new outdoor classroom and rustic play equipment, including a swing and trampoline. Individual secure play areas have been introduced to the complex-needs building, providing students with a safe outdoor play space.
  • A new sensory facility has been provided with LED mood lighting and specialist equipment.
  • A new Life Skills classroom block has been added where the students can learn to cook, wash up, make beds, and clean bathrooms. The workshop provides students with opportunities for servicing bicycles.
  • The design involved reinstating original features, such as the roof structure and double height windows. Modern suspended ceilings were removed to reveal the original 1910 lathe and plaster double height ceilings. Natural daylight was increased, by introducing new high-level roof lights to classrooms and new artificial lighting was installed to comply with current regulations.
  • The retrofit involved installing an internal layer of insulation to the walls and roof of the external envelope, along with replacement single-glazed units with double-glazed windows and doors.
  • New, lightweight pods were added to the classrooms as internal quiet rooms with warm fresh air being delivered via heat recovery units.
  • A new heating system was designed, using fan coil units, that were integrated into new, internal teaching walls to avoid equipment being surfaced mounted in each classroom.

New outdoor classroom
Reinstating original features such as the roof structure and double height windows
Introducing renewable energy such as solar power

A Better Solution

  • Reusing redundant buildings instead of demolishing and rebuilding.
  • Retaining historic features and enhancing the surrounding character setting.
  • Retrofitting buildings to current building standards to comply with regulations.
  • Upgrading existing building fabric to improve thermal performance and energy efficiency.
  • Provide a new build classroom facility fabricated offsite to Passivhaus principles.
  • Introduce renewable energy such as solar power and air source heat pump.
  • Decarbonise by reducing demand on energy and reduce C02 emissions by removing fossil fuel.

Collaboration

  • The design brief for the renovation of the buildings was established through a series of online meetings between Dorset Council, Beaucroft College and BoonBrown in the autumn of 2021.
  • The wider college community was invited to view the proposals and have their say.
  • The comments from the college were incorporated into the proposed designs.
  • Monthly design team meetings were held onsite, giving the design team an opportunity to discuss issues and resolve problems.
  • In the spring of 2023, the students were invited to site to view their new facilities and to see the progress that had been made from the initial drawings into reality.

Student tour of college building works
Insulation to the internal face of the existing building’s envelope to improve thermal efficiency

Innovation

  • The project involved a holistic approach to renovation and decarbonisation pulling together engineers and architects.
  • The installation of insulation to the internal face of the existing building’s envelope to improve thermal efficiency.
  • Passivhaus principles were used for the new life skills classroom block, using an insulated slab to form the foundations, eliminating cold bridging. The main structure used a timber frame that was prefabricated offsite.

Floor Plans


1.Entrance foyer
2.Reception/ office
3.Classroom
4.Life skills classroom
5.Staff room
6.Hygiene room

7.Office
8.I.T
9.Kitchen
10.Post 16 common area
11.Store
12.Courtyard
13.Sensory area

Sections

Section AA
Section BB

A. Concrete flat roof
Suspended lay in grid ceiling. 150mm thick existing concrete flat roof. 0.25mm Polythene 1000 gauge vapour control layer laid on top of concrete plank and lapped up walls above insulation. Minimum thickness 120mm Xtratherm tapered insulation laid on top of concrete roof followed by a layer of roofing membrane.

B. Sloping ceiling
146mm Metal ‘C’ stud fixed to existing rafters running parallel. 80mm Xtratherm XT/PR in-between ‘C’ studs. 80mm Xtratherm XT/ PR face-fixed to metal stud. 25mm service void created using timber battens. One layer of 15mm British Gypsum Sounbloc mechanically fixed back to service void battens. All joints to be taped and finished with a skim and paint decoration finish. Metal Stud fixing detail to original building to be as per S.E details.

C. Flat ceiling
100mm mineral wool insulation laid between existing rafters on top of lath and plaster ceiling. 150mm mineral wool insulation laid on top of existing rafters. Overall insulation thickness of 250mm.

D. Ventilated roof tiles
To be installed high-level to create required airflow in roof space.

E. External wall thermal upgrade
50mm Air Gap from existing structure, 92mm Metal Stud with 60mm Xtratherm XT/PR in between webs. 60mm Xtratherm XT/PR face-fixed to metal stud. 25mm service void created using timber battens. One layer of 15mm British Gypsum Sounbloc mechanically fixed back to service void battens. All joints to be taped and finished with a skim and paint decoration finish. Metal Stud fixing detail to original building to be as per S.E details.

F. Flat roof
15mm plasterboard fixed to underside of existing joists. Timber firrings to ensure roof is laid at a minimum fall of 1° minimum. 18mm plywood laid on top of firrings with 0.25mm polythene 1000-gauge vapour control layer on top and lapped up around insulation on all sides. 120mm Xtratherm FR-ALU insulation with roofing membrane on top.

G. Photovoltaic panel

H. New roof light

I. Existing window
Openings to be infilled with matching brickwork and backing block. New brickwork to be toothed into existing brickwork.