modern methods of construction

Hanson Building ProductsHead OfficeStewartbyBedfordMK43 9LZ

Tel: 08705 258258Fax: 01234 762040

Website: www.hanson.biz/ukEmail: [email protected]

Hanson Building Products

Modern Methods of Construction

Hanson MMC Brochure MFX V2 11/7/06 5:22 pm

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Combining traditional buildwith modern performance

As one of the UK’s leadingmanufacturers of building products,Hanson has sought solutions to themain criticisms against traditionalbuild - speed, quality and wastereduction - and has developed itsown unique answers to ModernMethods of Construction.

By combining traditional techniqueswith modern factory-based processes,the company has been able to meetand exceed the exacting requirementsof current and future buildingregulations.

At the same time, Hanson hasprovided a safer working environmentfor the construction of standardisedsingle storey cavity walls withregulated work patterns and assuredquality control, unaffected by inclementweather conditions.

Hanson – a single sourcesolution in prefabricatedbuilding products

With its market-leading position,Hanson has developed a range ofprefabricated building products thatenable housebuilders and developersto gain all the advantages ofquicker build times and quality ofworkmanship. By using traditionalbuilding materials, the Hansonproduct range satisfies therequirements of end users who,consistently favour traditionallybuilt homes.

Modern Methodsof Construction

Exterior Walling Systems

Interior Walling Systems

Flooring Systems

Basement Systems

Staircases

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6-11

12-15

16-19

20-21

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Hanson Building ProductsA range of innovative systems using Modern Methods of Building Construction

Contents

Hanson MMC Brochure MFX V2 11/7/06 5:22 pm Page 3


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Wonderwall Panel SystemAircrete Blocks Hollowcore SuspendedFlooring System

Dense BlockWalling

Basement Twinwall SystemConcrete Staircase

MMCOff-site manufacturing utilising technically advanced prefabrication processes for better build quality and efficiency

With mounting emphasis to increaseboth the number of houses built andthe efficiency with which they are built,Modern Methods of Construction havenever been more relevant. Hanson is inthe forefront of leading UK constructionproduct manufacturers to be offeringinnovative solutions that meet the needsof efficiency and acceptability.

Using the accumulated skill and expertisegained through its wide-rangingoperations, Hanson is now able tooffer a range of related products. The‘Hanson House’ provides prefabricatedsolutions from basement, through groundand first floors - and including staircases- to external and internal walls.

In all instances, products have beendeveloped to take advantage of advancedprefabrication processes. The productshave been designed and developedto maximise the benefits of off-sitemanufacturing processes in thecontrolled environments of purpose-

built factories, whilst minimising theneed for on-site involvement that issubject to the unpredictability of boththe weather and the availability ofskilled labour.

Unlike the prefabricated housing builtduring the 20th century, much of whichwas designed to be temporary, the focusof Hanson’s MMC compliant products ison quality of materials and workmanship.In more recent times prefabricationhas been successfully used for theconstruction of hospitals, hotels andschools in the UK as well as for housingin other countries. This helps to providethe assurance of building methods andmaterials that have been tried andtested in use. Whilst quicker build timesare the ultimate goal, they are notachieved at the sacrifice of qualityof design and workmanship.

Hanson MMC products are providedwith the full backing of the company’stechnical advisory service.

Modern Methods of Construction

Jetfloor InsulatedFlooring System

OmniaFlooring System


WonderwallLightweight cladding panel system with high quality clay brick slips

Hanson’s Wonderwall claddingsystem combines all the advantagesof modern prefabrication with all theappeal of traditional appearance. It canbe installed faster than traditionallybuilt masonry to a higher level of qualityand is suitable for use as a durable,decorative and thermal insulating finishto external vertical walls. Existing or newbuild structures that use masonry, denseconcrete, modular units, timber or metalframes are all suitable for fixing.

The system comprises a rigid urethaneinsulation panel which Hanson pre-bond to a vacuum-formed brickworkco-ordinating carrier sheet. Thecomposite panel is fixed back to thesubstructure on site, and brick slips arefixed to the carrier sheet using a purpose-made adhesive. A specialist pointingmortar completes the installation.

A wide variety of brick finishes areavailable, including extruded and stockfacing slips. Different brick bonds


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such as stretcher, stack, Flemish andEnglish can be easily achieved.

Brick details such as corbels and dentilcourses can be incorporated by alteringthe thickness of the finishes from15mm to 35mm. External corners,soldier courses and reveals can beachieved by the use of L-shaped pistolslips. Being lightweight, Wonderwallprovides a method of finishing areaswhere traditional brickwork cannot beincorporated, such as staggered gablesor balconies on framed structures.

Wonderwall also provides on-siteflexibility to enable shaping to suitopenings and other building details,whilst minimising wastage.

Exterior Walling System

Hanson House, BRE, Watford

Prefabrication benefits with traditional finish

Brick slip installation process


LockCladTerracota cladding system with high quality clay sigma tiles

The Red Bank LockClad system providesan external rainscreen façade that issuitable for most types of construction,including concrete, timber and steelframed buildings and can accommodatecurved facades, corners, angles, windowand door openings.

The system comprises of sigma claytiles, sigma aluminum support rails andclips. The primary support structure andthe sigma rails can be fully installedbefore tiling commences. Installationis fast and simple and can be effectedin any direction and sequence. Each LockClad sigma tile is securelyand independently retained on thesupporting rail by fixing clips, allowingindividual tiles to be removed andreinstated. LockClad sigma is designedto be fixed to most substrates - including


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masonry, concrete, steel and timber framesystems and lightweight walling panels.

LockClad sigma is designed to functionas a rear-ventilated, open-jointedrainscreen cladding. As with mostrainscreens, it allows the insulation to belocated on the outer face of the buildingshell. This provides efficient insulationand reduces the risk of thermal bridgingand condensation problems.

LockClad sigma has been subjected torigorous independent testing to establishits high performance criteria. Thiscovers all aspects of durability, strength,water penetration, fire, impact andmaintenance. LockClad is the firstterracotta rainscreen to be awarded aBritish Board of Agrément Certificate.


A ventilated rainscreen and decorative terracotta façade

Each tile is securely and independently retained

External rainscreen façade


GluedbrickworkThin-joint glued brickwork

Developed several years ago in Europe,thin-joint glued brickwork is appropriatefor a wide range of building types, fromdomestic construction - particularlywhere several dwellings are constructedon the same site allowing efficient useof equipment - to large commercial andcivil engineering projects.

The technique relies on joints which areformed using an adhesive or glue mortar,that have a high percentage of cement,very fine inert additives and speciallyformulated polymers. The adhesive isapplied by using specially developedhand-held pumped nozzles that usuallydispense two parallel beads of materialalong the horizontal bed joints and on theperpends prior to the bricks being laid.

Many metres of bed joint adhesive canbe laid in a rapid single operation, withthe nozzle dispensing relatively accuratequantities of mortar. Working conditions,speed of construction and overall qualityare generally considered better thanthose of traditional mortar.


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High compressive, flexural and tensile strengths are achieved

Easy application

University of West of England Allowing scope for creative bond patterns

A variety of finishes can be achievedthrough the flexibility of brick type andthe scope for creative bond patterns asa stretcher bond is no longer necessaryfor the structural strength of the wall.

The compressive, flexural and tensilestrengths of thin-layer mortars arehigher than that of common mortars.This leads to an increased bond strengthmeaning lintels can often be omitted,and facilitates the simple use of un-reinforced stack bonding. The gluemortar’s permeability is less than thatof common mortars. This, togetherwith the thinness of the joints, tendsto minimise water penetration throughthe mortar zone.

Perhaps the greatest potential forthin-joint glued brickwork lies withprefabricated panels either in a factoryor at a construction site. Prefabricationis particularly useful for congested citycentre sites, buildings with rapidconstruction programmes and whenthere is local bricklayer shortage.


BlockworkPrefabricated thin joint dense concrete blockwork panels

Thin joint adhesive technology, employedfor on-site construction in Europeancountries for more than a decade, hasnow been developed by Hanson tocreate fully prefabricated thin jointdense concrete block panels. Providingease and speed of construction onsite, the panels offer the mechanicaladvantages of strength, soundinsulation and fire resistance, whilstminimising wastage. They are suitablefor use on ground and first-floor levelsand because of their weight and highload bearing capacity, are equallysuited to multi-storey construction.

The strength provided by thin jointconstruction enables the panels to befully prefabricated in the factory andtransported and installed on site. The


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Purpose made corner panel

panels consist of a 100mm outer leaf,a 100mm inner leaf and a 100mminsulated cavity, and can be used with avariety of internal and external finishes,including dry lining systems, plaster,paint or specialist cladding panels suchas the Hanson Wonderwall System.

Factory manufacture mirrors the manualblocklaying approach although thelaying rate using a bespoke mortarapplicator can be up to three timesfaster than traditional trowel layingtechniques. Prefabrication moves thewet trade off site and into the controlledenvironment of a factory to provideconsistent quality not subject to thevagaries of the weather and variationsin skill levels.


Installation of prefabricated panel

Ease and speed of working on site

Masonry Option

In addition, prefabricated inner leaf denseblocks can be used in conjunction withsingle brick skin masonry which maybe built up on site or as panels in afactory environment.



AircreteBlocksThin joint lightweight concrete blocks

Thin joint lightweight aircrete blocksprovide a fast, clean and accuratemethod of construction that isdesigned to lower costs by reducingthe time taken to build walls. By usingThermalite’s Thin Joint Mortar andAircrete Blocks the depth of mortar canbe reduced from 10mm to 3mm or less.

The application of thin joint mortar tothe blocks is quickly and accuratelyachieved by the use of a serratedscoop, the full benefits being realisedon long runs of wall. Independentspeed trials have indicated that awall of Thermalite blocks and thinjoint mortar can be laid twice as fastas that built with aggregate blocksand general use mortar. The speed ofconstruction can be further enhancedby using Thermalite Large FormatBlocks, which have a face size oftwo traditional concrete blocks.

Thin joint mortar sets more rapidlythan traditional mortar and istypically stable after 60 minutes.This allows the amount of walling thatcan be built to be increased and theearlier installation of other componentssuch as floors and roof timbers. The completion of a weathertightenvelope allows brickwork to be takenoff the critical path and for internalwork, such as service installation,partitioning and plastering to progress.

This method of construction alsoreduces heat loss through mortarjoints to provide improvements inU-values of up to 10%; improves theairtightness of the construction; andreduces wastage on-site by allowingfor the precision cutting of blocks.


Construction in progress

Saving time and costs in building walls

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Lightweight blocks for easy handling


JetfloorThe original insulated flooring system


Rapid and easy installation, no special skills required

25 structural topping with A98 meshor polypropylene fibres completesthe system.

The EPS blocks are supplied in lengthsof 550mm to enable rapid coverage oflarge floor areas. Services are easilyaccommodated by omitting blocks ortrimming them with a fine-toothed saw.Installation is simple and there is norequirement for special skills, equipmentor preparation.

Jetfloor Plus is an alternative systemwhich comprises inverted ‘T’ beamsinfilled with purpose-made EPS blocks,finished with either a floating 18mmthick chipboard layer, or 65mm sand/cement screed.

The thermal performance of bothJetfloor Super and Jetfloor Pluscan help significantly in meetingthe requirements of Part L of theBuilding Regulations.

Flooring Systems

Jetfloor Super

High levels of insulation with reduced construction costs

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Another example of Hanson market-leading innovation, Jetfloor Super is thefirst composite suspended system forground floors incorporating polystyreneinfill blocks to provide high levels ofinsulation, achieving U-values as lowas 0.20 W/m2K.

The integrated insulation effectivelyreduces the overall floor zone byobviating the need for sheet insulationmaterial, thereby reducing constructionheights. In this way, Jetfloor Superactually reduces construction costs.Contractors also benefit from thesystem’s speed and simplicity of usethat makes for rapid and easy installation.This enables floors to be finished earlyin the construction process, allowing forearlier drying out and faster follow-onfor other trades.

The system consists of standard 150mmdeep inverted ‘T’ beams at a maximum of610mm centres, infilled with expandedpolystyrene (EPS) blocks. A grade


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HollowcoreFor suspended floors with clear spans up to 13 metres

Hanson prestressed hollowcoreunits are ideal for all suspended floorapplications, particularly where a clearspanning durable deck is required. Withclear, unpropped spans of up to 13metres, they can be used on masonry,steel or concrete structures, offeringbenefits of fast erection and theprovision of an immediate workingplatform.

With excellent sound and fire resistantproperties, the units can be suppliedwith preformed service holes andnotches. The Hanson range, now themost extensive available in the UK,increases the versatility of the productenabling flooring solutions to be tailoredto projects. The structural propertiescome from the prestressing strands


cast into the lower half of the units -the number of strands and the degreeof prestressing determining theultimate load/span capacity. Whenconcreted together hollowcore unitscan provide diaphragm action withoutstructural topping. However,enhanced structural performance isachieved by usinga composite structural topping.

All units are machine produced ensuringconsistently high quality with the steelbeds producing a smooth regular soffit.

Solid composite flooring units offer thesimilar benefits to hollowcore but,being thinner, enable a wider range ofcomposite solutions for a given floorzone. Manufactured to the same factory

Flooring Systems

Suspended floor application

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standards, they are available 100mmdeep and in widths up to 1200mm.Unpropped spans can be constructedup to 5 metres, with propping enablinggreater spans. Full technical adviceis available.

Fully participating formwork

A direct equivalent to an in-situ slab,Omnia enables pre-cast and in-situconcrete to be combined to give majorbenefits to specifiers, engineers andcontractors.

Acting as a fully participating formwork,Omnia is fast to erect saving time andmoney. Its exceptional flexibility enableseach panel to be designed to suit aspecific location and load, with irregularlyshaped buildings being easilyaccommodated. Service holes andthe like are positioned and formedduring manufacture.

Panels incorporate the Omnia lattice

girder manufactured from cold drawnwire. The girder is cut to size andattached to a lower layer of reinforcement.Concrete is then poured to create theprecast panel. The lattice girder ensuresa mechanical bond between precastand in-situ concrete.

Standard panels are 2.40 metres wide(smaller panels can be manufactured toorder) and between 50mm and 75mmdeep. Depending on loadings and overallslab depth, spans of over 11 metres canbe achieved.

The Omnia Flooring range includespanels incorporating polystyrene void

OmniaWideslab flooring combining pre-cast and in-situ concrete

formers, perimeter edge formwork orinsulation, or can be manufacturedusing lightweight aggregate to provideweight savings of over 20%.


TwinwallTwin benefits from a combination of precast and in-situ concrete

Using prefabricated panels comprisingtwo slabs connected by means of cast-in lattice girders to form a single unitinto which concrete is poured on site,Hanson’s Twin Wall is a fully flexiblewalling system that combines thespeed and quality of precast concretewith the structural and waterproofintegrity of a continuously poured insitu concrete structure.

Without restriction on architecturallayout, the system eliminates the needfor expensive formwork and the waitingtime for the removal of formwork toprovide for fast build, with installationrates of up to 100m2 per hour.

No edge shutter is required whenpouring upper floor concrete and


plastering to ceiling is not necessaryto achieve a high quality finish.

The panels are machine manufacturedto exacting tolerances and canincorporate cast-in cable ducts,electrical boxes and service ports.They are supplied complete with floor,window, door and ventilation openings.Once installed, panels provide superiorsound insulation.

By reducing weight, prefabricated TwinWall panels provide savings in bothtransport and crane costs.

Full computer design with detailedinstallation drawing, calculation andmethod statement can be suppliedfor each project.

Basement Systems

A fully flexible walling system with complete design freedom

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Crane installation

Pre-cast concrete unit

The UK’s largest producer of BoxCulverts, Hanson manufactures awide range of precast concrete unitsfrom 1000mm x 600mm to 6000mmx 3600mm with flat or shaped inverts.Traditionally used for water transportation,Box Culverts are exceptionallyversatile and can be used not only for

basements but also for above groundapplications such as garages.Manufactured in rapid hardeningPortland cement, or combined rapidhardening Portland cement and pfa,they meet Class 3 and Class 4 soilconditions respectively.

Box Culverts


StaircasesPrecast stairs and landings for domestic and commercial projects


Excellent sound insulation

• straight flights with cross landings - ideal where side support is available for both main and half landings

• flights with integral top and/or bottomlandings - suitable for steel framed buildings or where fewer crane lifts are preferred.

Hanson also produces the uniqueUniflight winding staircase, which isavailable in both L and U configurations.Designed to emulate traditional timberstaircases with winders radiating roundthe Newell Post, Uniflight offers areduced plan area over alternatives,together with excellent sound insulationand a high quality ex-mould soffit,suitable for direct decoration.

Winding staircases can be installed as thebuilding progresses, providing immediateand safe access to following floors.

Staircases

Uniflight staircase in domestic property

Quality-controlled factory production for rapid construction

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Straight flight

Individually designed and manufactured,precast concrete staircases combinethe advantages of quality-controlledproduction with rapid construction andimmediate access for follow-on trades.

The Hanson range now includes bothstraight flight and winding staircasesin both standard and bespokearrangements. Suitable for virtuallyany situation in most masonry, concreteand steel structures, they requireno propping or formwork and areinherently fire resistant.

Where a standard mould is not suitable,a comprehensive bespoke design andmanufacturing service is available.Standard moulds are available for:

• short flights with integral top and/ or bottom landings - ideal for locatinground lift shafts


Hanson Building ProductsHead OfficeStewartbyBedfordMK43 9LZ

Tel: 08705 258258Fax: 01234 762040

Website: www.hanson.biz/ukEmail: [email protected]


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