the structural insulated panel building system€¦ · the structural insulated panel building...

The Structural Insulated Panel Building System

design

engineer

manufacture

supply

erect

www.innovaresystems.co.uk

2

THE COMPANYQuality from design to project completion

Innovaré provides a totally integrated service in the design, engineering, manufacture,

supply and erection of Structural Insulated Panel (SIP) building systems for a complete

range of public and private housing, education, commercial and leisure projects.


The challenge

Just a few short years ago, SIP systems represented something

of an unknown quantity in the construction industry.

Back then, Innovaré Systems was one of the few companies

to recognise their potential in a climate that was placing a

growing importance on sustainability and low carbon

building methods.

Today, SIPs have become a recognised alternative to traditional

building methods and we are the leading provider of bespoke

systems that offer flexibility, performance, thermal efficiency

and value for projects of every kind.

It’s our aim to go on challenging the UK construction industry

to think differently about the way it builds and to embrace

new methods and new materials that contribute to a more

sustainable future.

Investing in the manufacturing process

Innovaré was founded in 2004 with the support of South

East-based contractors, Osborne.

In 2008, Osborne extended that support with a significant

investment in the launch of I-S Manufacturing and a state

of the art production line for the i-SIP building system

in Coventry.

Since then, our customers have enjoyed the benefits of a

completely integrated supply chain, from computer aided

design and precision controlled production, to scheduled

delivery and on-site project management services.

The result is more predictable costs and build

programming, reduced waste and ongoing commitment

to product development to ensure even more efficient

and sustainable solutions.

3

Design Engineer Manufacture Supply Erect

Quality from design to project completion

Andrew Osborne, Deputy Chairman, Osborne

We’re proud to partner Innovaré in the

development of ever more efficient and

sustainable building solutions to help specifiers,

contractors and end users alike to benefit from

the many advantages of the i-SIP system.

• Design. A meticulous CAD plan using the latest

3D modelling technology, overseen by our expert

design team.

• Engineer. i-SIP panels are engineered to deliver

maximum structural, hygrothermal, fire resistance

and acoustic performance in a composite structure

that is more than the sum of its parts.

• Manufacture. Each i-SIP panel and component

is a bespoke product, manufactured in precision

controlled conditions using premium quality

sustainable materials.

• Supply. Delivery to site, with each individual i-SIP

component packaged in order of use for ease and

efficiency to meet strict construction schedules.

• Erect. On-site support and advice from Innovaré

Systems Project Managers.

Unique proposition

i-SIP allows the construction industry to adopt more off-site

techniques and has encouraged a shift away from more

traditional building methods towards assembly on-site.

Effectively, construction can now be an extension of the

production process, with all the same benefits of precision,

efficiency and quality control.

We plan projects from the outset to ‘design out’ complexity

and waste and to maximise those efficiencies for a better

value, better quality finished product, without compromising

on architectural design.

4


i-SIP combines versatility and adaptability for any project application

PRODUCTS


i-SIP based dry structure

The i-SIP dry structure comprises external and party structural

walls; floor cassettes; truss roof rafters or i-SIP roof panels;

and load-bearing and non load-bearing partitions.

Structural wall components are made of OSB (Orientated

Strand Board) Type 3 to BS EN 300 with an expanded

polystyrene core manufactured to BS EN 13163 under

quality assurance standard ISO 9001.

Partitions are assembled from CLS C16 timber, supplied

under PEFC and FSC forest stewardship standards.

Floor cassettes can be fabricated with metal web beams for

easy services access, I-beams for longer or unsupported spans

or in hollowcore concrete, if appropriate.

i-SIP roof panels are between 111mm and 307mm thick and

up to 6 metres long. This warm roof construction provides

valuable extra loft space in a fully insulated ‘room in the roof’.

Other core insulation materials can be specified.

i-SIP panels for infill

For use as infill in steel, concrete or glulam timber frame

structures, large format i-SIP panels offer a cost efficient infill

solution for a variety of rainscreen, cladding or render finishes.

Although designed for non-structural applications, they meet

the same EC5 compliance standards as i-SIP for structural

projects, providing both durability and peace of mind with a

projected performance life of over 60 years.

In addition, their modern, modular installation method

makes them quick and easy to work with in comparison

with traditional building methods; contractors have achieved

coverage of up to 500 square metres per day and enjoyed

considerable savings in time, materials and labour as a result.

As with the i-SIP dry structure, other core insulation

materials can be specified.

The i-SIP system offers a range of panel thicknesses to deliver

various U-values.

U-values (W/m2K)

Panel thickness

(mm)

100E expanded polystyrene

(EPS)

Low Lambda EPS

Low Lambda EPS+Tyvek

reflex

111 0.31 0.29 0.25

136 0.26 0.24 0.21

162 0.22 0.20 0.18

206 0.18 0.16 0.15

257 0.14 0.13 0.12

307 0.12 0.11 0.10

Based on a 4% timber content

5


i-SIP combines versatility and adaptability for any project application

The benefits at a glance

Choosing i-SIP offers advantages on so many levels and

at every stage of the construction process:

• Versatility: Create and realise ambitious architectural

features.

• Efficiency: Offsite construction cuts time and saves

on labour and materials costs.

• Sustainability: Less waste in manufacture, low carbon

footprint and recyclable raw materials.

• Reduced running costs: Enhanced thermal efficiency,

limited cold bridging and exceptional airtightness for

highly efficient buildings.

• Build quality: Computer aided design, modular build

and limited post construction settlement.

i-SIP system components

• Roof panels are suitable for flat or pitched roof

applications and ‘room in the room’ construction to

expand the usable footprint within the building.

• Roof trusses provide a cost-effective option and

traditional approach to roof structure.

• External wall panels are available in various thicknesses

for different thermal performance (see table opposite).

• Internal partitions for load-bearing, non load-bearing

and also for use as party walls.

• Floor cassettes are assembled in large format in both

web and I-beams, as required.

• Infill panels provide non load-bearing infill for steel and

concrete frame stuctures and are engineered for wind

load and racking resistance.

6


In-house manufacturing to guarantee your supply chain

PROCESS

Advanced manufacturing facilities

I-S Manufacturing is a sister company to Innovaré Systems

Limited and was launched following significant investment

from Osborne.

Located in Coventry, it consists of 33,000 sq ft of cutting edge

design and manufacturing technology for the production of the

i-SIP system and is home to a hi-tech production line capable

of producing panels in any thickness from 111mm to 307mm

and any size up to 6 metres x 2.7 metres.

The production process

Working in close consultation with project architects, our

system designers take project plan drawings and render them

as 3D computer models to test the design concept and identify

any possible build issues.

The latest scheme design software is then used to produce a

detailed manufacturing specification that is sent directly to the

production line.

The unique configuration of I-S Manufacturing offers huge benefits, both economic

and material, ensuring a cohesive supply chain.

Each i-SIP panel is produced to precise parameters and in

‘build sequence’ to allow for quicker assembly once on-site.

Panels consist of a layered composite formed from OSB outer

panels around an expanded polystyrene insulation core, with

timber end closers to add further strength and stability.

These layers are then bonded under pressure, using state

of the art adhesive and press technology, to form a unit that

offers exceptional load-bearing capabilities with little or no

need for additional structural reinforcement.

CAD design

Production

CNC machining

Quality assured assembly

7


In-house manufacturing to guarantee your supply chain

Quality assurance

All i-SIP manufacturing processes and products are closely

monitored and tested to ensure ongoing quality

and performance.

The i-SIP building system has received third party

accreditation from a number of construction industry

regulators and is approved by the BBA in a programme

that includes rigorous quality assurance inspections of the

processes involved in the supply chain.

Investment and innovation

Innovaré pursues a policy of constant investment to push

the boundaries of performance and sustainability in

i-SIP construction.

We also participate in development programmes with industry

partners, including the BRE, to encourage innovation and

champion affordable solutions in sustainable building design

and construction.

We have the capability to laminate a wide range of substrates, including;

• Plasterboard • MDF

• PUR/PIRslab • Steel/Aluminium

• EPS • CementitiousBoard

• XPS • Foils

• MineralWool • Fabrics

• GlassFibre • PVC

• OSB • Polypropylene

• Chipboard • Polycarbonate

8


Performance and standards, guaranteed

ASSURED

A positive environmental impact

Sustainability is a key driver in every aspect of our operations.

The I-S Manufacturing facility has been carefully planned

to reduce levels of waste to the barest minimum. All timber

treatments are water based and all materials, wherever

possible, are 100% recyclable.

Even its location, Coventry, was chosen for its easy links to the

motorway network to allow for a reduction in vehicle emissions.

Other environmental advantages offered by i-SIP include:

• PEFC certified timbers

• OSB manufacturing process utilising virtually 100%

of the tree

• Reduced energy consumption through excellent

thermal performance and airtightness

• Zero global warming and ozone depletion potential

Meeting the regulations

The i-SIP system offers a range of panel thicknesses to deliver

various U-values. See table on page 4.

All panels exceed Building Regulation requirements for

30 minute and 60 minute fire resistance.

Similarly, i-SIP panels provide acoustic insulation performance

over and above minimum levels required by the regulations.

UK SIPS Association

Innovaré is a founder member of the UK SIPS Association,

an organisation established to champion the use of SIPs

and establish best practice for their use across the

construction industry.

The Innovaré i-SIP system is approved by the BBA, NHBC and LABC and satisfies

Building Regulations for England, Wales, Scotland and Northern Ireland.

The Association provides advice on technical issues for

specifiers and contractors and gives SIPs manufacturers and

suppliers a platform to communicate and collaborate on the

advancement of SIPs for the greater benefit of the industry.

Experience

We have completed several projects with high sustainability

and thermal performance requirements - here are some

examples;

7 houses, Charlton, London – CSH Level 5

• Specifiedasi-SIPwith50mmPURcavityinsulation

• U-value–0.14W/m2K

• Airpermeability–1.8m3/m2/hr

• Airtightnessachievedthroughadditionalmastic

around joints and seals

2 flats, Redhill – CSH Level 5

• Specifiedasi-SIPplus50mmEPScavityinsulation

• U-value–0.15W/m2K

• Airpermeability–4m3/m2/hr or less

• UpgradedroofinsulationtoachieveU-valueof0.13W/m2K

7 houses, Windsor – CSH Level 5 & 6

• Specifiedasi-SIPplus50mmPURcavityinsulation

• U–values:

Externalwall–0.14W/m2K;

i-SIPpitchedroof–0.16W/m2K

• Airpermeability–5m3/m2/hr

• UplifttoCSHlevel6fromphotovoltaiccellstoensure

development maintained uniformity

9


Design freedom

FOR ARCHITECTS

Single point of responsibility

We control the i-SIP supply chain from the initial design

stages, through engineering and manufacture to on-site

assembly. That gives us a deep understanding of your

project and gives you a single, accountable point of contact

throughout the whole process.

Design flexibility

Designing with i-SIP doesn’t limit architectural ambition.

Although panellised buildings have a different structural

behaviour, taking the build method into account from the word

go eliminates inefficiencies and incompatibilities and allows for

complex designs, without compromise.

Meeting and exceeding expectations

i-SIP building envelopes offer exceptional thermal efficiency

and airtightness. The system consistently exceeds Building

Regulations and has been used in a number of projects with a

sustainability mandate in line with the CSH or PassivHaus.

Technical support

A full technical support service is available at every stage of

your project to help you exploit the full potential of i-SIP. This

covers detailed 3D CAD drawings through to on-site project

management during assembly.

Guide to i-SIP construction

A comprehensive guide to designing and building with SIPs,

produced with the architect and designer in mind. Explaining

the principles of the i-SIP system, the guide gives clear and

impartial advice on best practice for i-SIP construction.

Download your copy from our technical zone at:

www.innovaresystems.co.uk/sips-guide

Sustainable materials

The i-SIP manufacturing process is geared to maximising

resources and reducing waste. i-SIP panels and other

componentsaremadefromGreenGuideA+ratedsustainable

materials and PEFC certified timbers. Once erected, i-SIP

buildings require minimal heating, substantially reducing

carbon emissions.

10


Eight ways i-SIP makes a better building system

FOR CONTRACTORS

1. Single supply chain i-SIP design and manufacture is managed in a dedicated production facility in Coventry, giving

us complete control over the design and quality of everything from the raw materials to the

finished product.

2. On-site services Our on-site project management team will oversee the assembly process, remaining

responsible for the progress of the scheme until the point of handover to the client or main

contractor.

3. Speed of installation i-SIP panels are loaded onto delivery vehicles in build sequence and with all apertures pre-cut

to make erection quick and easy. A typical 95m2 structure can be completed in two days.

4. Factory quality standards State of the art scheme design software and stringent quality control ensure accuracy and

tolerances to +/- 2mm, reducing the margin for error and the possibility of delays on-site.

5. Large format panels With individual i-SIP panels available in lengths of up to 6 metres, buildings can be

completed more quickly and airtightness improved through a reduction in the

number of panel joints.

6. Health and Safety management Health and safety on-site is our top priority. Every stage of the construction process is assessed

for risk in line with good on-site practice and specific plans are drawn up for each scheme in

close consultation with the contractor.

7. Financial backing Innovaré Systems is a wholly owned subsidiary of South East-based contractors Osborne.

Their continued investment allows us to make constant improvements in the design and

production quality of the i-SIP system, and gives you peace of mind regarding the stability

and viability of your supplier.

8. Off-site build Off-site construction techniques cut waste and reduce the need for on-site storage

of components.

i-SIP achieves a 90% reduction in the costs of post-construction remedial work over alternative methods of construction.

11


The working and learning environment that has

been created has made a massive difference

to the students and staff. In addition to these

benefits we have seen savings in our energy and

maintenance costs, so we’re very pleased.

Ann Scales, School Business Manager,

Davison High School

Eight ways i-SIP makes a better building system Quality and peace of mind built-in

FORBUILDINGOWNERS

Speed of build

The rapid assembly made possible by the i-SIP system

reduces overall build time and lowers overall construction cost,

as well as bringing forward handover and occupation.

An accredited, quality product

The i-SIP system has been assessed and approved by the

BBA and has been accepted by the NHBC and LABC. Our

own testing and quality assurance processes further guarantee

performance, adding still further to your peace of mind.

For the owner, an i-SIP structure offers a host of benefits, not least, quality, comfort,

energy efficiency and value for money.

Superior energy efficiency

The high thermal performance and superior airtightness of

a finished i-SIP structure will help save energy and reduce

running costs from day one. This provides occupiers with

considerable cost savings whether in the residential, leisure,

commercial, healthcare or education sectors.

Low environmental impact

Because reduced energy means reduced emissions, i-SIP

contributes positively to the environment by helping to lower

CO2 levels. In addition, all the materials used in manufacture

and construction are sustainable and 100% recyclable.

Fewer post-construction defects

The structural integrity of the i-SIP system eliminates

settlement after building completion, reducing the time

required for post-construction snagging and allowing

occupants to take up residence sooner, without the

aggravation of ongoing remedial work.


12


APPROACH

The result is superior quality control and complete customer

assurance, coupled with production and cost efficiencies that

shorten build times and bring down final costs.

By talking to us at the very beginning of a project, our holistic

approach to design and build allows us to understand your

precise requirements and translate then into workable

schemes that deliver more cost effective solutions.

Those solutions will be completely bespoke to your

specifications and produced in a seamless supply chain in

whicheverymemberoftheInnovaréteam–fromdesign

throughmanufacturetoassembly–sharesacommonvision

and goal for a successful, sustainable, practical

and efficient building.

The Innovaré i-SIP system is a wholly unique offer. We are the only major provider to

control procurement, design, manufacture and assembly processes for our i-SIP system

from start to finish.

We aim to minimise risk for our customers

and provide a controlled, single point of

responsibility for our i-SIP system. We combine

this with our project experience, technical

knowledge and capability to deliver on time,

within programme and to budget.

Andrew Orriss, Managing Director,

Innovaré Systems


Design

i-SIP design methodology optimises material usage whilst

engineering out waste and inefficiency from the finished

product, leading to more efficient buildings and more cost

effective construction.

• Advanced 3D CAD technology

• Specialist production control software

• Precision design for precision assembly

• Early consultation with architects

Engineer

i-SIP panels follow the principle of composite material

construction to deliver a product whose load-bearing capacity,

structural integrity and hygrothermal, fire resistance and

acoustic performance exceeds those of any individual component

within the system. In addition, all materials are guaranteed

sustainable under international certification schemes.

• External walls: Two types of expanded polystyrene to

BS EN 13163, sandwiched between 11mm OSB Type 3.

Breather membrane to external face

• Party walls: 89mm of expanded polystyrene, additional

50mm sound quilt

• Timber frame party wall options using 89mm stud frame

• Sole plates, fixings and screed rails included

• OSB skins support structural loads, expanded

polystyrene filling stabilises envelope. Timber sole plates

transfer loads to screed rails and foundations

Manufacture

Our hi-tech production line is the result of serious investment

in manufacturing systems and in research and development.

Providing a standardised operation for consistent and precise

results, the manufacturing process is driven by industry

leading software and overseen by professional

and experienced line operators.

• Produces a 6 metre long panel every 12 minutes

• Automated CNC router provides tolerances of +/- 2mm

Supply

Our control over the supply to site of the i-SIP system provides

maximum efficiency and reduced build times. Delivery is

carefully scheduled to match the progress of the assembly

and minimise the need for material storage on-site. A clear

project management schedule is made available to everyone

- architect, main contractor and clients - along with detailed

drawings and structural calculations supported by BBA

Certificate number 08/S040

• Off-site construction saves time and money

• Fewer trades and workers on-site improves

health and safety

• Efficient delivery vehicle loading reduces movements

and repeat visits to the site

15


Erect

On-site assembly is co-ordinated by an Innovaré Systems

Project Manager to offer the main contractor advice on

erection and assembly throughout the whole process.

Full risk assessments and Health and Safety plans

are provided.

• Panels offloaded in correct assembly sequence

• 12 to 18 hour assembly time for average family house


16


The people and skills that provide a premium service

TECHNICALEXPERTISE

Track record

As leaders and pioneers in SIPs and product design, we

can count among our staff some of the most qualified and

experienced authorities in structural insulated panels and their

application in the construction industry.

Several of our senior members of staff sit on the UK SIPS

Association advisory panel, helping to champion not just

i-SIP, but SIPs as a generic building system to architects

and contractors alike.

Our customer relationships

As with most innovative methods, it’s important that customers

new to SIPs technology liaise closely with us in order to

understand and exploit the full potential of our system.

Our Technical Support Team offers help and advice on i-SIP

for building design, as well as remote and on-site support

to help contractors manage the assembly process.

That support extends to a comprehensive build programme

and a clear agreement of how responsibilities will be shared

between Innovaré Project Co-ordinators and main contractors.

Our people are proactive, professional and dedicated to providing a service that matches

our product for performance and efficiency.

Sales support

You’ll find our sales support staff attentive, helpful and

efficient. Aided by an accurate and robust quoting system,

they’ll help you buy more efficiently and implement your

project more cost effectively.

The project team have been helpful, responsive

and positive, totally committed to achieving the

finished build on time, always solving any issues

effectively and with minimal fuss.

Trevor Tilley, RDjW Architects

17


The people and skills that provide a premium service

www.innovaresystems.co.uk www.innovaresystems.co.uk

18

Innovaré policies and publications

POLICIES

Environment

How our choice of suppliers, materials, partners and processes

serves to reduce waste and conserve resources.

Sustainability

How i-SIP reduces energy consumption and lowers emissions

through thermal performance and enhanced airtightness.

Corporate social responsibility

How our approach to business partnerships, procurement

and colleagues supports our CSR goals.

Equality and diversity

How we encourage growth, personal development and equal

opportunities among our workforce.

You’ll find all the relevant corporate policies available to download from our website,

at www.innovaresystems.co.uk/policies

Health and safety

How we manage health and safety for the wellbeing

of customers, contractors and the public.

Waste management

How we seek to minimise waste through our choice

of materials and manufacturing processes.

19


20


Our track record in i-SIP construction

EXPERIENCE

CASE STuDy 1Affordable Homes, New Cross, LondonOur i-SIP system was specified to achieve level 3 of the

Code for Sustainable Homes on this development of

11 houses and 42 flats. We provided a high quality,

thermally efficient envelope which reduced the need

for post-construction snagging.

Client: Hyde Housing

Contractor: Osborne

Architect: HTA Architects

CASE STuDy 2Affordable Homes, Charlton, LondonHigh performance building envelope using our i-SIP panels

for seven new homes in South London which meet the

requirements of level 5 of the Code for Sustainable Homes.

Client: Family Mosaic Housing Association

Contractor: Osborne

Architect: BPTW Partnerhip

CASE STuDy 3Ward Extension, StockportInnovative infill solution for a new neo-natal unit using large

format i-SIP panels where speed of installation was critical

to minimise disruption on-site.

Client: Stockport NHS Foundation Trust

Contractor: W.Carefoot & Sons Ltd

Architect: Taylor Young Architects

21


CASE STuDy 4Accommodation Centre, East SussexLarge format i-SIP panels achieved exceptional U-value and

thermal performance for a new accommodation centre with

the benefits of speed of build.

Client: London Youth Trust

Contractor: Farnrise Construction

Architect: RDjW Architects

CASE STuDy 5Private Executive Development, Hampshirei-SIP structure integrates with thatched roofs to meet strict

planning requirements and provide a thermally efficient

structure for a development of 3 large executive homes

in Hampshire.

Client: Bricks & Mortar Property Development

Architect: Richard Ashby Associates

CASE STuDy 6Affordable Homes, Tottenham Restrictive and challenging project for 44 unit mixed

use affordable housing scheme in North London, including

a three storey construction of our i-SIP panels on top of a

concrete frame structure.

Client: London & Quadrant Housing Association

Contractor: Osborne

Architect: Ankur Architects

22


Our track record in i-SIP construction

EXPERIENCE

CASE STuDy 7New Hospital Ward, StevenageAn upgrade and expansion of the Lister Hospital used

an innovative infill solution using i-SIP panels to provide

a thermally efficient envelope. Innovaré completed the

installation in 10 days.

Client: East & North Hertfordshire NHS Trust

Contractor: Osborne

Architect: AD Architects

CASE STuDy 8School Extension, WorthingSix classrooms, a staffroom and new toilet block for a school

extension delivered within a tight build programme. The dry

structure was completed in seven days, reducing the total

build schedule by 13 weeks.

Client: West Sussex County Council

Contractor: Joynt Construction

Architect: John Whiting Architect

CASE STuDy 9Affordable Homes, CroydonInnovative ‘room in the roof’, using 587m2 of i-SIP roof

cassettes to maximise usable space for a challenging

development of 13 affordable homes in Croydon with

restrictive site access.

Client: London Borough of Croydon

Contractor: Osborne

Architect: Michael Cook Associates

23


CASE STuDy 10Hotel, Stratford, Londoni-SIP infill solution for a 260 room hotel constructed on top

of a shopping centre as part of the Olympic development in

Stratford, East London. Innovaré constructed the top 10 stories

from 30 up to 65 metres using 3000m2 infill panels.

Client: Whitbread

Contractor:EnglishArchitecturalGlazing

Main Contractor: Westfield Construction

Architect: Axiom Architects

CASE STuDy 11Sustainable Homes Development, RedhillThe first inhabited Code for Sustainable Homes level 5 project

in the UK in collaboration with Energy Saving Trust, Tandridge

District Council and Osborne.

Client: Raven Housing Trust

Contractor: Osborne

Architect: Harrington Design and Bloomfield Architects

CASE STuDy 12Affordable Homes, KentChallenging rural development within a flood plain which

included 12 homes built off the ground level prior to the

structural envelope being completed.

Client: West Kent Housing Association

Contractor: Osborne

Architect: Woodward Ambose Architects

Innovaré Systems Limited

Unit B Earl Place Business Park,

Fletchamstead Highway,

Coventry

CV49XL

Tel: 0845 674 0020

Fax: 0845 073 0800


email: [email protected]

FSC logoand statement

Printed on 100% recyclable chlorine-free paper.All inks used on this brochure are vegetable based.

the structural insulated panel building system€¦ · the structural insulated panel building...

Documents