innovation _ by nyut545e2

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									showcasing achievements in construction products



innovation &
achievement 2008
contents   Message from the Chairman
           Message from the Secretary of State,
           Department for Innovation, Universities and Skills
                                                                           4


                                                                           5


           health, safety & security                                       6
           Adams Rite Ltd Sentinel 6 Deadlock                              8
           John Brash & Company Ltd JB-RED Pre-Graded Roofing Battens
                                                  ®
                                                                           9
           Lafarge Plasterboard Ltd GTEC Aqua Board                       10
           Leaderflush Shapland Hygieniform                               11
           Marley Waterproofing LCMS Roofing System
                                           20
                                                                          12
           Naylor Concrete Products Ltd Ultra-Fire                        13
           British Gypsum Gyproc Ergo900                                  14
           JELD-WEN UK Ltd FireGuard                                      15
           Marshalls Mono Machine Lay Tegula Block Paving – Sandy Works   16
           Marshalls plc Pallet Rationalisation Project                   17
           PCE Limited Slingsafe - Tamworth                               18
           Permanite Engineered Roofing Systems SafeStick prevENt         19
           Polyflor Ltd Polysafe Wood FX                                  20
           Quarry Products Association Sharing Good Practice 2007/08      21
           The Steel Construction Institute Trojan Horse Health
           and Safety Messages                                            22
           Beresford’s Flooring Limited SLAPP Clamp - Ashbourne           23
           Beresford’s Flooring Limited Hole Cover - Ashbourne            24


           energy & carbon saving                                         25
           British Gypsum Road to Rail Transfer Scheme                    27
           Dulux Trade from AkzoNobel Dulux Trade Ecosure                 28
           Hanson UK Recycled Cold Mix Asphalt                            29
           Kingspan Insulated Panels Kingspan EnergiPanel                 30
           LB Plastics Limited Sheerframe HED                             31
           Marshalls plc Reduction in Compressed Air                      32
           ABM Bridge Systems RENAULT F1 TEAM CFD CENTRE, ENSTONE         33
           Aggregate Industries Sustainability                            34
           Celotex Celotex XR3200                                         35
           Corus Colors Confidex Sustain    ®
                                                                          36
           H + H UK Limited Compressors Project - Pollington              37
           Hanson Formpave Water Recycling & Geothermal Heating           38
           Lister Trade Frames Limited Elitis Energy A+ Windows           39
           Marley Eternit Energy Management & Employee Awareness          40
           Marshalls plc Block Plant Compressed Air Management            41
           Marshalls plc Sustainability and Carbon Impact Reduction       42
           Redland Redland Solar Water Heating System                     43
           SIG PLC eviee                                                  44
           Tarmac Topblock Online Code for Sustainable Homes              45
           Wolseley Wolseley Sustainable Building Center                  46
           Worcester, Bosch Group Greensource Air to Water Heat Pump      47
contents   improvements in site efficiency
           Ancon Building Products Ancon Lockable Dowel
                                                                                    48
                                                                                    50

cont.      CEMEX Viadeck
           Charcon Road-Pod
                                                                                    51
                                                                                    52
           Knauf Drywall Brio Dry Floor                                             53
           Milton Pipes Limited Quickchange Moveable Barriers (QMB)                 54
           Polypipe Building Products Polysoak                                      55
           Aggregate Industries Pedestrian & Traffic Segregation - Ashington Site   56
           Dow Building Solutions INSTA-STIK Multi-Purpose Fast Cure
                                                 TM
                                                                                    57
           Redland Rapid Vented Ridge Universal System                              58
           Saint-Gobain Isover Isover RD 35 Construction System                     59
           Saint-Gobain Isover UK Climaver Plus R Ductwork System                   60


           resource efficiency                                                      61
           Altro Safety Floor Recycling System                                      63
           ASSA ABLOY Door Solutions ASSA CLIQ Electronic
           Master Keying System                                                     64
           Bradstone Rainwater Harvesting System                                    65
           Forticrete Gemini Roof Tiles                                             66
           Profile 22 Systems Ltd RCM – 100% Recycled Reinforcement
           for Windows & Doors                                                      67
           Tarmac Topblock Take Back Scheme                                         68
           Aggregate Industries Plastic Recycling                                   69
           Aggregate Industries Sustainability Through Recycling                    70
           Aggregate Industries Recycle Water, Silt and Energy Reduction            71
           British Gypsum Thistle Durafinish                                        72
           Marshalls Mono Waste Reduction                                           74
           Polypipe Eco-Vat Home                                                    75
           Profile 22 Systems Ltd Post Consumer and Industrial Waste PVC-U
           Windows & Doors Recycling Service                                        76
           Tarmac Precast Concrete Recycling of Waste Materials                     77
           Hanson Building Products Working Together to Reduce
           Waste - Ipswich                                                          78
           Bovis Lend Lease in conjunction with 2K Manufacturing
           RePlas Hoarding                                                          79
message from the
construction products
association chairman

As Chairman of the Construction Products                                          infrastructure and of course the industry’s products are key to
                                                                                  delivering a better, more efficient, more sustainable built environment.
Association I am delighted to have this opportunity
to introduce the 2008 edition of Construction                                     As a showcase of some of these products and processes, interest
Products Innovation and Achievement, which now                                    in CPIA has always been keen and this year is no exception. We
in its fifth year, is established as a leading showcase                           are enormously grateful for the response by companies throughout
for some of the most innovative products and                                      the industry that have submitted their entries to CPIA 2008. It is
                                                                                  always a tough decision deciding which ones to feature, but you can
processes that have been developed by the                                         be sure that for each one chosen there are plenty of others that
industry in the previous year or so.                                              could equally demonstrate the innovative achievements and exciting
                                                                                  development of the construction products industry.
Once again the industry has proved its enormous ability to embrace
innovation, across the board and deliver new and exciting solutions               CPIA was always intended to feature a range of solutions so as to
to the construction industry. As you will see from the range of                   show how the industry as a whole is at the forefront of innovation,
products and processes chosen, both here in the publication and also              improvement and change. At a time where there is increased
on the Association’s website, this creative and innovative approach is            economic uncertainty, we can all be proud that our industry
not confined just to a select few in one or two sectors, but can be               continues not only to aim high but also to continue to deliver
seen as a key driver for an industry that is continuously improving               these improvements.
and constantly changing. By delivering efficiencies and demanding
savings, these new ideas bring a range of benefits to everyone from
company employees, to clients, customers and ultimately end users.

The construction products industry continues to be one of the
largest sectors in UK manufacturing, accounting for an enormous
20% of all manufactured goods. With sales of more than £40billion,
the industry currently represents four per cent of GDP. It is at                  Adrian Barden
the heart of the UK economy and provides essential products                       Chairman
for our homes, schools, hospitals, factories, offices and transport




4                             innovation & achievement 2008 (electonic version)                                                construction products association
message from the
secretary of state,
department for innovation,
universities and skills
I am delighted to introduce this showcase of                                       Framework Programme 7 research calls. FP7 could represent
                                                                                   a significant opportunity for the UK construction industry. We
innovative products and achievements in the
                                                                                   are also supportive of the EUREKA platform - EurekaBuild -
construction sector. It is a sector worth over                                     which brings together companies involved in the construction
£100bn a year, accounting for 8% of Gross                                          sector from across Europe to undertake joint research.
Domestic Product (GDP) and providing
employment for around 3 million workers.                                           Our Building Colleges for the Future programme will have invested
                                                                                   about £5bn to ensure that colleges and training providers are
The construction industry faces an exciting challenge over the                     equipped with state-of-the-art facilities by 2010. I am personally
next few years. We must reduce the environmental impact                            committed to drive change and use Government procurement
of the built environment if we are to have any chance of                           to create markets for new innovative products by making sure
meeting demanding targets for carbon and other emissions.                          that our environmental standards for new college buildings are
                                                                                   among the highest in the world. From this year, all new capital
We want to lead the world in sustainable construction and                          projects will be expected, where possible, to meet the new,
deliver a radical change in the sustainability of the construction                 revised “Excellent” Building Research Establishment standards
industry. The recently published joint Industry and Government                     for environmental performance. We are continuing with an
strategy for Sustainable Construction highlighted specific                         energy efficiency grants scheme to help all colleges reduce
actions to be taken by industry and by Government. These can                       their carbon emissions. And we have set the ambitious goal
contribute to the achievement of overarching targets within                        that by 2016, all new college buildings must be zero carbon.
each of the main areas covered by the sustainability agenda.
                                                                                   More will be needed and my Department is committed to playing its
Creating ‘zero carbon’ buildings cost-effectively, and in the                      role in ensuring that we are building the best framework of support,
numbers required, will need innovative products, materials                         developing the skills of our people, and carrying out world class
and processes. A great deal is already happening.                                  research and scholarship. By applying both knowledge and skills UK
                                                                                   companies can seize new opportunities and remain a global success.
The business focused Technology Strategy Board has established a
Low-Impact Buildings Innovation Platform to help industry deliver
‘zero carbon’ buildings. It also provides support for a range of other
initiatives including the Modern Built Environment Knowledge Transfer
Network to help industry identify and exploit emerging technologies,
which will be critical to the continued success of this sector.

Through the European Construction Technology Platform                              Rt Hon John Denham MP
(ECTP), liaising directly with the European Commission, the                        Secretary of State, Department for Innovation, Universities and Skills
industry is now better able to influence European Research




5                              innovation & achievement 2008 (electonic version)                                               construction products association
innovation & achievement 2008
health, safety & security
With the revised Approved Code of Practice              Designers and Specifiers can help meet
for the Construction Design and Management              their obligations under CDM by choosing
Regulations, there is additional emphasis on the        products that improve safety both for
duty of designers to consider safety throughout the     installers and users as well as enhance security,
whole life cycle of the building, from construction,    which is also of increasing concern.
through to usage and including end of life decisions.
                                                        Manufacturers have again responded positively
                                                        with a variety of products and solutions
                                                        addressing some of these key responsibilities.
innovation & achievement 2008
health, safety & security




Adams Rite Europe Ltd
Sentinel 6 Deadlock
The Sentinel 6 is a mortise mechanical deadlock which has specifically
been designed for the commercial aluminium door market.

The Sentinel 6 operates with a 17mm Europrofile cylinder,
has a 14.5mm wide case, is available in three backset sizes
(25, 30 and 40mm) and will retro fit into the current
Adams Rite Europrofile Deadlock preparation.

The Sentinel 6 has been designed to meet the stringent requirements
of BS EN 12209, the European single point mechanical lock standard
and achieves security grade 6; the first for this type of lock.

To achieve security grade 6 the Sentinel 6 must withstand
10,000N of side load and 6,000N of end load on the
bolt, outperforming all other locks in its class.




    What is innovative or new?                                                      Contact details
    The Sentinel 6 is the first lock for aluminium doors that                       Contact:     Andy Stolworthy
    meets the stringent security levels of BS EN 12209.                             Address:     Adams Rite Europe Limited
                                                                                                 The Meadows
    In conjunction with Adams Rite cylinder and security                                         Cannock Road
    escutcheon this aids door systems to meet the attack                                         Wolverhampton
    levels now being demanded by the market.                                                     WV10 0RR
                                                                                    Telephone:   0845 8734838
                                                                                    Email:       andy.stolworthy@adamsrite.co.uk
                                                                                    Website:     www.adamsrite.co.uk
    How are benefits delivered?
    The Sentinel 6 provides greater security compared to its
    predecessor due to its lack of ‘smile’ and combined strength
    of a bar bolt and anti-spread feature of a hook bolt.

    Its slim-line lock case has specifically been designed to
    fit easily into Thermally Broken Aluminium sections as
    well as retro-fitting into single chambered sections.




8                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




John Brash & Company Ltd
JB-RED® Pre-Graded
Roofing Battens
Timber battens are a crucial element in holding roof tiles in
place. Although BS5534:2003 states only graded battens should
be used, it is not prescriptive where this should be done.

Before the introduction of JB-RED®, grading of roofing battens
had been carried out on site. However, this often led to problems
due to lack of training, basic understanding of British Standard
requirements and more often than not local site conditions. The
result was that sub standard battens often made it onto the roof.

The problems of poor grading on site were illustrated recently
by a house builder in East Anglia. On this particular site a tiler fell
through the roof and a subsequent inspection found that even
though the batten had been graded on site, sub standard battens
had made it onto the roof. Stepping onto one of these battens that
had cracks and knots outside BS5534:2003, had caused the accident.
The House builder immediately changed to JB RED® on all sites.


    What is innovative or new?                                                     Contact details
    JB-RED® is the only pre-graded roofing batten fully complaint                  Contact:     Linda Wilson
    with BS5534:2003. Volume grading of roofing battens is a                       Address:     John Brash & Company Ltd
    highly complex operation and required major investment by                                   The Old Shipyard
    the company in laser scanning equipment capable of scanning                                 Gainsborough
    250m of battens every minute. Two lasers, two high resolution                               Lincolnshire
    cameras and eight computers carefully select the compliant                                  DN21 1NG
    batten, which are guaranteed not to have defects beyond                        Telephone:   01427 613858
    those allowed in BS 5534:2003.                                                 Facsimile:   01427 810218
                                                                                   Email:       lwilson@johnbrash.co.uk
                                                                                   Website:     www.johnbrash.co.uk

    How are benefits delivered?
    Tilers rely on the strength of the batten when working on
    the roof (they may be used as an alternative to roof ladders,
    if they are attached to rafters no more than 540mm apart).
    However, if they are not graded properly sub-standard
    battens may fail when they are being used for this purpose.

    The increasing frequency of high winds and severe storms
    in the UK means that it is important to use correctly
    graded battens because they are a vital contributor to
    the long term strength and robustness of the building.




9                              innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
health, safety & security




Lafarge Plasterboard Ltd
GTEC Aqua Board
GTEC Aqua Board is a gypsum based plasterboard that is water
and mould resistant. It is a multi purpose board that can be used
in a number of wet area applications saving time and money.

1. As an internal lining board in areas of high exposure to water and
   moisture, ranging from kitchens and bathrooms to swimming pools.

2. It can be used for a range of external applications, such as a
   sheathing board on structural steel and timber framed applications.

3. It can be used on any building which is not weather tight.

As it is a gypsum based board there are a number of benefits:
    • Easy to fix, using standard screws
    • Easier to cut, no saw required
    • Lighter than cement based board, easier to handle (10.8kg/m2)
    • Sound and fire resistant – meets Part B & E Building Regulations
    • Can be left directly exposed to weather
       conditions for up to six months on site.


     What is innovative or new?                                                     Contact details
     Aqua Board is unique as it is the only gypsum based                            Contact:     Simon Scrase
     board suitable for severe wet area applications. It                            Address:     Lafarge Plasterboard Ltd
     provides outstanding performances including:                                                Marsh Lane
        • Water resistance in areas of high humidity                                             Easton in Gordano
           and areas exposed permanently to water                                                Bristol
        • No mould and fungi growth                                                              BS20 0NF
        • Sound and fire performances to meet                                       Telephone:   01275 377 773
           current building regulations                                             Facsimile:   01275 377 550
        • 100% recyclable.                                                          Email:       simon.scrase@lafarge.com
                                                                                    Website:     www.lafargeplasterboard.co.uk


     How are benefits delivered?
     1. Lighter than cement particle boards
        therefore easier to handle on site
     2. Easier to cut and fix, no special tools required
     3. Can be left directly exposed to all weather
        conditions on site for up to six months. No longer
        does an installer need to wait before a building
        is weather tight, saving time and money
     4. Board and compound are 100% recyclable
        – Supports sustainable practices
     5. Total system solution for wet area applications.




10                              innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
health, safety & security




Leaderflush Shapland
Hygieniform
Hygieniform is a 2mm through colour, high impact PVC facing
option for performance doorsets which incorporates the
antimicrobial additive – Hygienilac® a biocidally proactive additive
which kills bacteria and other microbes by preventing their access
to nutrients. It does not employ silver technology, rendering it
completely UV stable and remains effective for years because of
its inherently low water solubility. It has passed British Standard
6250 tests for severe usage and its active ingredient has approvals
from the Food and Drug Administration (FDA), Health and Safety
Executive (HSE) and the Environmental Protection Agency (EPA).
Hygieniform incorporates the Hygienilac® anti-microbial additive
through the complete 2mm thickness of the PVC so that even
if the surface is scratched, it will still provide protection against
harmful bacteria such as C.diff, E.coli, Salmonella, Listeria and MRSA
making it an ideal product for helping with infection control.




     What is innovative or new?                                                      Contact details
     Hygieniform is the only PVC door facing option in the market                    Contact:     Stephen Hutsby
     place that provides protection against C.diff. The anti-microbial               Address:     Leaderflush Shapland
     additive, Hygienilac, does not employ silver technology                                      Milnhay Road
     which means the effectiveness of the product does not                                        Langley Mill
     deteriorate with exposure to UV light, therefore Hygieniform                                 Notts
     doorsets retain their ability to combat HAIs (Healthcare                                     NG16 4AZ
     Associated Infections) for the life-time of the doorset.                        Telephone:   01773 530500
                                                                                     Email:       stephen.hutsby@leaderflushshapland.co.uk
                                                                                     Website:     www.leaderflushshapland.co.uk

     How are benefits delivered?
     Hygieniform faced doorsets are ideal for healthcare
     applications to help fight the spread of infectious diseases
     such as C.diff. Hospital environments are harsh and physical
     damage to doorsets is common place. Hygieniform not
     only protects the doorset from damage but also maintains
     its anti-microbial properties. The benefits of Hygieniform
     can be applied to various applications where hygiene is
     paramount, such as food processing, commercial kitchens,
     care homes and even educational environments.




11                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




Marley Waterproofing
LCMS20 Roofing System
LCMS20 is a two layer cold applied, flame free built up roofing system,
with a comprehensive 20 year guarantee. LCMS20 has addressed
current issues over health and safety and insurance premiums that
affect the client, specifier, installer, building users and general public.
It is because of these attributes that Marley Waterproofing has
named this system the Life Cycle Membrane System. The system
takes into account the design considerations of architects and
specifiers and the installation choices of today’s contractors to offer
a solution that meets customer requirements for a long lasting roof.
The result is the provision of a long lasting solution that retains a
traditional bituminous build up with a mineral finish. As the LCMS20
system uses cold applied technologies it is perfectly suited to projects
where bitumen boilers or gas torches are impractical. A result of
which is a reduction in the level of fumes and CO2 emissions.




     What is innovative or new?                                                     Contact details
     LCMS20 enables the cold application of traditional bituminous                  Contact:     Beth Barber
     roofing membranes. Whereas this would normally require                         Address:     Marley Waterproofing
     bitumen boilers or flame guns, the LCMS20 system uses                                       Covert Road
     self-adhesive bonding techology meaning that buildings                                      Aylesham Industrial Estate
     undergoing roof refurbishment do not need to be                                             Aylesham
     vacated during the work.                                                                    Kent, CT3 3EQ
                                                                                    Telephone:   01304 843300
                                                                                    Facsimile:   01304 843533
                                                                                    Email:       beth.barber@marleywaterproofing.com
     How are benefits delivered?                                                    Website:     www.marleywaterproofing.com
     The launch of LCMS20 has met a specific customer need for
     cold applied roof waterproofing with a traditional finish
         • 20 year guarantee covering materials, workmanship
           and design
         • Flame free - no requirement for hot bitumen or gas torches
         • Assists in reduced contractor insurance premiums
         • Reduced impact on the environment
         • Suitable for warm and cold roofs
         • New build or refurbishment
         • Approved Installer Network.




12                              innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
health, safety & security




Naylor Concrete Products Ltd
Ultra-Fire
Ultra-Fire is a pre-stressed concrete lintel with a unique fire
retardant coating (patent pending): this increases the fire resistance
by some 200% as compared to a standard pre-stressed product,
meaning that Naylor can offer 90 minutes fire rating on a 100mm
wide pre-stressed concrete lintel and 240 minutes fire protection
on 140mm and 215 mm wide pre-stressed concrete lintels.

The unrivalled fire resistant properties of Ultra-Fire allow
the architect or engineer to significantly improve the fire
rating of their building: this is particularly important in
projects such as hospitals and retirement homes where
greater evacuation times have to be allowed for.




     What is innovative or new?                                                      Contact details
     Naylor is in a unique position as the first lintel manufacturer                 Contact:     Helen Macintosh
     to have developed and having tested a range of                                  Address:     Naylor Concrete Products Ltd
     prestressed concrete lintels to meet modern day fire                                         Milner Way
     resistance requirements. The Ultra Fire product can solve                                    Ossett
     many problems for architects and engineers alike.                                            WF5 9JN
                                                                                     Telephone:   07778 460412
                                                                                                  01924 267286
                                                                                     Facsimile:   01924 265674
     How are benefits delivered?                                                     Email:       helen.macintosh@naylor.co.uk
                                                                                     Website:     www.naylorlintels.co.uk
     The enhanced fire resistant properties of Ultra-Fire enable
     architects and engineers to improve the structural fire
     resistance of their buildings. The resulting enhanced fire
     resistance of the completed structure may also provide
     future economic benefit for the client in the form of reduced
     insurance premiums. As an alternative, the architect or
     engineer may elect to maximise internal space and minimise
     build cost – effectively using a smaller profile lintel to achieve
     a fire resistance formerly only possible with a much bigger unit.




13                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




British Gypsum
Gyproc Ergo900
The new Gyproc Ergo900 board has been developed specifically
to meet the growing demand from customers, industry bodies
and the HSE, for construction products that support and promote
improved health and safety in the construction industry. Gyproc
Ergo900 is a 12.5mm thick, 900mm wide board, developed as part
of the GypWall CLASSIC system range for commercial applications
providing acoustic performance of up to 58dB, 120 minutes fire
performance, and HEAVY or SEVERE Duty rating to BS 5234.
The 2400mm long board has been engineered to meet the 25kg
maximum weight limit recommended for a single person lift, and
at 900mm wide Gyproc Ergo900 fundamentally improves the
ease of lifting and manoeuvrability of the board. The board has
also undergone an extensive programme of testing at the British
Gypsum Building Test Centre, and is the first 900mm wide board
to be fully performance tested and substantiated for a range of
typical commercial single and double boarded applications.




     What is innovative or new?                                                     Contact details
     The first ergonomically designed board to combine a                            Contact:     British Gypsum
     fully substantiated acoustic, fire and duty performance in                     Address:     Drywall Academy Advice Centre
     a 900mm wide single-person lift board. The board is part                                    East Leake
     of a three-stage approach involving new product, new                                        Loughborough
     advice on lifting and safe handling and recommendations                                     Leicestershire
     for use of specialist lifting equipment on site.                                            LE12 6JT
                                                                                    Telephone:   08705 456123
                                                                                    Facsimile:   08705 456356
                                                                                    Email:       bgtechnical.enquiries@bpb.com
     How are benefits delivered?                                                    Website:     www.british-gypsum.com
     The industry currently uses standard 1200mm wide
     plasterboard, but changes in Building Regulations have
     increased performance requirements and have changed
     board thicknesses and weights. The introduction of Gyproc
     Ergo900 and its supporting campaign will help to prevent
     injury resulting from manual handling and help to reduce
     the severity of injury for anyone involved in manual handling
     tasks through increased awareness and understanding.




14                              innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
health, safety & security




JELD-WEN UK Ltd
FireGuard
FireGuard is a 35mm thick 30 minute fire resisting door, the same
thickness as most non fire rated internal doors. It has been tested to
BS476 Pt 22 and is BWF CERTIFIRE industry approved, compliant
with Building Regulations requirements. It is compatible with standard
non-fire door frames / linings unlike other fire doors.

The product has pre-fitted intumescent fire seals essential in
achieving performance and protection. The design is incorporated
into the range of JELD-WEN internal fire doors as an alternative to
the 44mm industry standard.

The product is based on a combination of core materials
(magnesium oxide board and straw board) not previously used for
fire doors. Materials are sustainable and low cost. Design is subject of
Patent application.

The FireGuard door is designed and engineered specifically for domestic
housing: fire doors used in domestic applications have previously
been over-engineered derivatives of commercial building doors.


     What is innovative or new?                                                      Contact details
     • Industry FIRST                                                                Contact:     Ian Purkis
     • The newly developed core of the door is                                       Address:     JELD-WEN
       thinner, down to 6mm where required.                                                       Retford Road
     • The door is compatible with standard                                                       Woodhouse Mill
       doors frames (non fire rated)                                                              Sheffield
     • The door is lighter in weight                                                              S13 9WH
     • No special manufacturing facilities required                                  Telephone:   0114 254 2000
                                                                                     Facsimile:   0114 2542365
                                                                                     Email:       ian.purkis@jeld-wen.co.uk
                                                                                     Website:     www.jeld-wen.co.uk
     How are benefits delivered?
     • Makes installation of fire doors much simpler and significantly
       improves ease of protection of building occupants
     • Expands practical opportunities and market
       for fire safety improvements
     • Reduces inventory costs in supply chain
     • Creates opportunity for slimmer partition
       widths in buildings, increasing useable floor area,
       particularly beneficial in large developments
     • Will save more lives




15                               innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
health, safety & security




Marshalls Mono
Machine Lay Tegula Block
Paving – Sandy Works
To reduce manual labour and handling (a typical installation means
each man would install on average 40 sq.mtrs equating to 7.4
tonnes of concrete being lifted each day). This was achieved using
elements within the manufacturing and installation processes
of concrete block paving to improve both productivity and
profitability. A cluster formation of pavers was designed, which
when manipulated on site gives a random installation effect, but is
still similar to a traditional hand lay product and in addition retained
its rectangular format for handling by existing mechanical systems.
During initial trials of the design the rows were side shifted and
when coupled with a series of build-outs led to the desired effect.
Following on from this, further work was carried out with a leading
block laying system manufacturer to modify a standard laying head
clamp to ensure the correct offset. Final trials were carried out
in conjunction with a machine lay installer to ensure the product
delivered the installation, handling and cost benefits intended.




     What is innovative or new?                                                      Contact details
     By providing pavers packaged in a format ready to install at                    Contact:     Kevin Reynolds
     site, achieved by the use of innovative production techniques.                  Address:     Marketing Support Paving
                                                                                                  Lower Brier Lodge
                                                                                                  Brookfoot Works
                                                                                                  Sothowram
     How are benefits delivered?
                                                                                                  Halifax
     The majority of paving blocks installed are mechanically                                     HX3 9SL
     rather than manually handled from the raw aggregates to                         Telephone:   07786 174316
     the final pavement without compromising on cost, quality                        Email:       kevin.reynolds@marshalls.co.uk
     or speed of installation. This process alleviates the manual                    Website:     www.marshalls.co.uk
     lifting physical position that places a large amount of stress
     on forearms, wrists, hands and the spine/back of installers.




16                               innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
health, safety & security




Marshalls plc
Pallet Rationalisation
Project
Key customers requested that Marshalls supply pallets in a format
which is compliant with their racking infrastructure. New racking
in customer yards was not easily able to accommodate the variety
of pallet sizes supplied by Marshalls. Product had to be stocked on
the ground in yards which was not ideal for busy branches with
pedestrian and vehicular activity. There were also health and safety
risk created by overhanging pallets and there was wasted space
within the racking due to anomalous packs. The product was often
damaged in the yard. The new proposed format would enable
product to be stacked on racking and leave yard areas free from
traffic. A roll out was developed focusing on two key ranges in
Phase 1 to closely monitor the implications of changes. Feedback
could then be obtained before further, larger volume products were
changed in Phase 2. A ‘Six-Sigma’ approach was taken to understand
other benefits which could be achieved as a result of the changes.
Trials were undertaken with various 1200mm pallet concepts.




     What is innovative or new?                                                     Contact details
     The products are more sustainable:                                             Contact:     Phil Bunyan
        • The new design uses significantly less                                    Address:     Landscape House
          timber than the previous design.                                                       Premier Way
        • Reduced the environmental impact of production by                                      Elland
          using UK sourced timber rather than overseas sourced.                                  West Yorkshire
                                                                                                 HX5 9HT
                                                                                    Telephone:   01422 306532
                                                                                    Facsimile:   01422 306485
     How are benefits delivered?
                                                                                    Email:       philip.bunyan@marshalls.co.uk
     Two key ranges can now be placed in racking and removed                        Website:     www.marshalls.co.uk
     from the yard floor in customer yards. The quality and
     stability of the packs was improved, improving the safety
     of stacking and the movement of goods. We improved our
     pallet stock efficiency by reducing stock numbers and options.
     Our Licensor, The National Trust, were pleased that we have
     been able to deliver environmental savings to the range.




17                              innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
health, safety & security




PCE Limited
Slingsafe - Tamworth
SlingSafe is a safety platform and boom system devised, in the
first instance, for loading and offloading items from open delivery
vehicles in the UK construction sector. With more than one fifth of
all reportable UK work-related accidents occurring near vehicles,
PCE believes the system has the potential to reduce injuries and
fatalities across many industries. SlingSafe features two rotating
booms which can be extended over any large open delivery
vehicle. Both booms can be adjusted for height and length to cater
for all loads and situations. Personnel are secured to the boom
via a pulley system and fail-safe fall arrest device – much like an
inertia reel seatbelt – which automatically locks and prevents a
fall, should the wearer slip or stumble during loading or unloading
operations. A secondary safety cord can be adjusted personally by
the operative to ensure that the boom, to which they are attached,
follows them as they move about the vehicle. The safety lines only
locking during sudden movement caused by a slip, fall or stumble.




     What is innovative or new?                                                      Contact details
     PCE which specialises in design and construction of concrete                    Contact:     Chris McReynolds
     structures’ designed SlingSafe with its own operations in mind,                 Address:     PCE Limited
     but sees significant potential for the system throughout the                                 5 Mariner
     construction sector and across other industries. It has been                                 Lichfield Road Industrial Estate
     launched against a background where the Health & Safety                                      Tamworth
     executive is being ever more vigilant in enforcing regulations                               Staffordshire, B79 7UL
     relating to working at height and working on or near vehicles.                  Telephone:   01827 301020
                                                                                     Facsimile:   01827 301021
                                                                                     Email:       enquiries@pceltd.co.uk
                                                                                     Website:     www.pceltd.co.uk
     How are benefits delivered?
     Slingsafe is a neater, safer more user-friendly than the existing
     “clip-on” systems. It also actually works restraining a vertical
     fall, not allowing the operative to swing into the load or
     vehicle, with a unique boom system, which follows the
     workers around. It offers operatives unhindered movement.
     Both booms can be adjusted for height and length to
     cater for all loads and situations and has the potential to
     reduce injuries and fatalities across many industries.




18                               innovation & achievement 2008 (electonic version)                                         construction products association
innovation & achievement 2008
health, safety & security




Permanite Engineered
Roofing Systems
SafeStick prevENt
SafeStick prevENt is a high performance, self-adhesive, fire
safe bitumen membrane roofing system which requires
no naked flames during installation and features prevENt
Graphite Fire Wall Technology. This innovative product delivers
fire safety during installation as well as during service.

By incorporating graphite technology, prevENt membranes
afford a rate of heat release half that of standard polyester
membranes and offer the highest levels of fire performance.

As well as being used for full system installations, the SafeStick
prevENt membranes can also be used as detailing or fire break
materials at detail work, when using hot applied systems.




     What is innovative or new?                                                       Contact details
     During manufacture, the upper surface of the membrane                            Contact:     Nichola Clayton
     base carrier is coated with expandable graphite crystals.                        Address:     Permanite Engineered Roofing Systems
     During the heat of a fire, the graphite expands drawing                                       Appley Lane North
     the heat out of the combustion process and creating a                                         Appley Bridge
     ‘crust’ after expansion. This crust effectively forms a barrier                               Wigan
     against the flames, acting as a smoke suppressant and                                         Lancashire, WN6 9AB
     halting dripping from the underside of the roofing.                              Telephone:   01257 256097
                                                                                      Facsimile:   01257 255771
                                                                                      Email:       nclayton@ikogroup.co.uk
                                                                                      Website:     www.permanite.com
     How are benefits delivered?
     prevENt graphite technology is environmentally friendly
     and has a distinct advantage over many polymeric
     membranes as the fire retardant properties are provided
     without the use of halogen compounds. Therefore, in
     the event of a fire, prevENt membranes cannot give
     off toxic fumes from halogenated components.

     SafeStick prevENt meets the highest UK and European
     fire performance standards: EN 1187 Parts 1, 2, 3 and
     4 (BS 476: Part 3: 2004), hence the ‘EN’ in the name.




19                                innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




Polyflor Ltd
Polysafe Wood FX
Polysafe Wood FX is a vinyl safety flooring that combines all the
elements of traditional safety flooring – sustainable slip and extreme
durability – with eight different wood designs that create an appealing
aesthetic, especially in areas that want to avoid “institutional” looking
materials, such as care homes and hospitals.The hidden slip resistance
is built into the product in new manner, to allow the designs to
shine through and with a polyurethane reinforcement to avoid the
dirt spotting effect sometimes associated with safety flooring.

The product is 2.0mm thick, 2m wide in a 40m2 roll, matching
the most common format demanded by the marketplace. A
wood design is printed onto a PVC backing layer, which in turn
is topped with a 0.7mm clear PVC wearlayer that incorporates
aluminium oxide for slip resistance, polyurethane for easier
cleaning and an antimicrobial agent for improved hygiene.




     What is innovative or new?                                                      Contact details
     Achieving sustainable slip resistance to HSE standards                          Contact:     Simon James
     without detracting from the appearance of the wood design.                      Address:     Polyflor Ltd
     Using only clear aluminium oxide without the quartz, silicon                                 PO Box 3
     carbide or dark aggregates typically used in safety flooring, slip                           Radcliffe New Road
     resistance is as close to invisible as possible in a standard                                Whitefield
     2 metre sheet safety floor.                                                                  Manchester, M45 7NR
                                                                                     Telephone:   0161 767 1111
                                                                                     Facsimile:   0161 767 1188
     How are benefits delivered?                                                     Email:       sjames@polyflor.com
                                                                                     Website:     www.polyflor.com
     • Sustainable slip resistance - surface emboss and aluminium
        oxide within wearlayer work together to maintain slip over
        the guaranteed life of the floor
     • Easy cleanability due to polyurethane reinforcement
     • Wood designs of outstanding clarity give a more homely, less
       institutional appearance
     • Low VOC emissions (AgBB Test) benefits indoor air quality.
     • Hygiene – incorporation of antimicrobial agents inhibits
        growth of bacteria such as MRSA
     • Antistatic – does not accumulate static (EN 1815) to
       protect user form static shocks




20                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




Quarry Products Association
Sharing Good
Practice 2007/08
This 60-page guide summarises the ideas and innovations
from the QPA’s Health & Safety Best Practice Awards 2007,
as part of our Industry’s drive to achieve ZERO Injuries. In
addition to the hard copy booklet, entries can be viewed at
www.Safequarry.com, where those from the previous seven
years of the QPA’s Awards Scheme can also be accessed.

The guide is a compilation of solutions that companies have
applied to minimise and where possible, eliminate health and
safety risks arising from their operations. The ideas and innovative
approaches are often simple and inexpensive and can readily
be applied to a range of common industry problems.

Divided into nine sections, this QPA Guide indicates
which entries were prize winners, and which have
video clips available. To help locate entries relating to
a certain subject, a keyword index is provided.


     What is innovative or new?                                                      Contact details
     The guide’s contents relate to the QPA’s H&S Awards                             Contact:     Martin Isles
     Scheme entries during the calendar year 2007. QPA                               Address:     Quarry Products Association
     utilises seven independent expert Judges. As part of                                         38-44 Gillingham Street
     their reviews, the Judges accept only new ideas or                                           London
     improvements/developments of existing ideas.                                                 SW1V 1HU
                                                                                     Telephone:   020 7963 8000
                                                                                     Facsimile:   020 7963 8001
     How are benefits delivered?                                                     Email:       isles@qpa.org
                                                                                     Website:     www.qpa.org
     By communicating good practice, both via hard copy                                           www.safequarry.com
     and electronically, via www.safequarry.com Each item is
     accompanied by direct contact details to assist interested
     readers. The resources are ideal for training purposes
     and for Continuing Professional Development (CPD). By
     reviewing this guide, particularly those sections relating to an
     individual’s main areas of work, solutions will be recognised
     that could be applied within his/her own workplace or
     they will generate an idea for an alternative solution.




21                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




The Steel Construction Institute
Trojan Horse Health
and Safety Messages
Trojan Horse messages convey good practice safety information
through eye-catching, simple pictorial messages on brightly
coloured backgrounds. They are attached to construction
products or equipment so that site operatives see the relevant
message just as they are about to carry out a task.

Trojan Horse messages show safe and unsafe ways of
carrying out a task. They are applicable to all types of projects
and do not interfere with the construction process.

The messages are applied to the products at the factory as site
managers do not necessarily have time to go around the site
attaching messages to products. By getting product manufacturers
involved in the application of the messages, it is easier and more
likely that the messages will also reach the smallest contractors.




     What is innovative or new?                                                     Contact details
     Trojan Horse messages are a cheap and simple                                   Contact:     Nancy Baddoo
     way of improving site safety. They are more eye-                               Address:     The Steel Construction Institute
     catching than conventional safety messages and are                                          Silwood Park
     strategically placed so that they are noticed at the                                        Ascot
     critical moment. Since they are pictorial rather than                                       Berks
     textual, they can be easily understood by everyone.                                         SL5 7QN
                                                                                    Telephone:   01344 636525
                                                                                    Facsimile:   01344 636570
     How are benefits delivered?                                                    Email:       n.baddoo@steel-sci.com
                                                                                    Website:     www.steel-sci.org / www.trojan-horse.org
     Trojan Horse messages are a timely reminder to
     site operatives of how to carry out an activity
     safely. They reinforce and remind operatives of the
     conventional safety training they have received.

     The simple pictorial messages are not language dependent
     and so are globally applicable. They are also appropriate to
     the changing profile of the UK construction workforce which
     now includes a large number of migrant workers, unfamiliar
     with language, local working practices and safety cultures.




22                              innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
health, safety & security




Beresford’s Flooring Limited
SLAPP Clamp - Ashbourne
Moving and unloading palletised products on site can be
difficult due to load stability problems. The traditional answer
to the problem is standard brick forks. These are comparatively
large and heavy, making them awkward in use and difficult
to man handle on site. In addition, the load can be relatively
unstable due to the lack of upper load clamping.

The SLAPP clamp is a lightweight solution, with a unique upper
self clamping mechanism and, 1.5 tonnes S.W.L. to ensure the
safe handling of palletised loads. Easy to use, the tines are placed
through the pallet and lower / lift the SLAPP clamp on top of the
load. Connect the four chain hooks to the tines and shorten as
tight as possible using the adjuster clutch. The chains should be
equal in length and this has been made easier by colour coding
the chain links.

Closing to just 6˝ wide when not in use, the SLAPP
Clamp also offers significant ease of transportation and
site storage compared to traditional alternatives.


     What is innovative or new?                                                    Contact details
     • Adjustable self clamping mechanism to top of load.                          Contact:     Chris Massey
     • Adjustable load height up to 1100mm.                                        Address:     New House Farm
     • Folds to just 6˝ wide for ease of transit / storage                                      Belper Road
     • Lightweight in comparison to conventional brick forks                                    Bradley
                                                                                                Ashbourne
                                                                                                Derbyshire, DE6 1LP
                                                                                   Telephone:   01335 345111
     How are benefits delivered?
                                                                                   Facsimile:   01335 345222
     • Colour coded chain links to ensure equal                                    Email:       chris@bfl.uk.com
       chain lengths to adjust load depth.                                         Website:     www.beresfordsflooring.co.uk
     • Securely clamps down on pallet ensuring load stability.
     • Clamp arm compression can be adjusted to suit the load.
     • Self returning clamp mechanism ensures
       minimum size for handling.
     • Net attachment points provided for safety net.
     • Carry handles provide eases handling.
     • Reduced overall lift weight increases crane
       safety factor for any given radius.
     • 1.5 Tonnes Safe Working Load.




23                             innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
health, safety & security




Beresford’s Flooring Limited
Hole Cover - Ashbourne
Both pre-formed and post drilled service holes in flooring pose a
significant hazard to site operatives. As a result of this risk, ankles
have been broken / sprained and shins badly cut / bruised. The
“traditional” practice of cutting timber boarding to place over holes
can be time consuming, creates a trip hazard due to the board
thickness and are easily dislodged as they are often not fixed down.
The surface of the timber can also be slippery underfoot.

The Beresford’s Hole Cover provides a strong, thin, high visibility, anti-
slip, cost effective and quick to install solution to this problem. This
enables sites to remove the element of risk at the earliest possible
opportunity, i.e. fitting them at the time of core drilling service holes,
or when installing precast flooring incorporating pre-formed service
holes. The covers are produced in two sizes to protect holes up to
300mm square and are easy to install. For holes up to 150mm just
squeeze the legs, place over the hole and push down. For larger
holes, plastic wedges can be inserted between the legs providing
additional outward pressure making it more secure. Alternative
security can be achieved by screw fixing.


     What is innovative or new?                                                      Contact details
     • Engineered Solution (Inc. load analysis)                                      Contact:     Chris Massey
     • Pre-formed                                                                    Address:     New House Farm
     • High Visibility                                                                            Belper Road
     • Anti - Slip                                                                                Bradley
     • Reusable                                                                                   Ashbourne
                                                                                                  Derbyshire, DE6 1LP
                                                                                     Telephone:   01335 345111
     How are benefits delivered?                                                     Facsimile:   01335 345222
                                                                                     Email:       chris@bfl.uk.com
     Quick and easy to install, power tool free installation,                        Website:     www.beresfordsflooring.co.uk
     removal and replacement. Strong, highly visible, anti-slip
     and recyclable and because of the reduced thickness, the trip
     hazard is lessened.




24                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving
Both carbon saving and reduced energy                   present the industry with a difficult and uncertain
consumption are key targets of the                      future and manufacturers and suppliers have
government’s sustainability objectives, which           been at the forefront of developing new
address the climate change challenge to                 initiatives to both minimise energy consumption
deliver a cleaner, greener economy.                     and use alternative sources of energy.

By combining developments in policies including;        Through CPIA, the construction products
long-term targets for Part L of Building Regulations;   industry demonstrates how it has addressed
the launch of a Code for Sustainable Homes; and         these challenges by managing the energy used
the EU Emissions Trading Scheme, the government         in the manufacturing processes as well as by
has expressed its desire to improve energy              manufacturing products that both reduce carbon
efficiency of buildings and reduce CO2 emissions.       emission and improve energy efficiency.
The supply and cost of energy continues to
innovation & achievement 2008
energy & carbon saving




British Gypsum
Road to Rail
Transfer Scheme
British Gypsum is continually looking to maximise use of more
environmentally friendly rail deliveries for both major raw material
deliveries into its plants and deliveries of finished products from
plants. Thereby reducing vehicle-based carbon dioxide emissions and
road congestion. British Gypsum delivers finished products from
its Kirkby Thore plant to customers in Scotland by rail, which has
removed 1.76 million lorry miles per year from the road network
and lowered its carbon footprint by 80% per load. Alongside this
in June 2008 British Gypsum signed a £16-million contract with rail
freight specialist, First BGRf, to deliver gypsum to its manufacturing
plants at Kikby Thore, East Leake and Robertsbridge. More than
80% of all UK raw material gypsum deliveries have now moved
from road to rail, bringing significant environmental benefits.




     What is innovative or new?                                                     Contact details
     In partnership with one of the UK largest transport specialist,                Contact:     Jo Doxey
     British Gypsum is the only plasterboard manufacturer                           Address:     British Gypsum
     capable of delivering such significant quantities of raw                                    Head Office
     material and finished product by rail. Reducing its carbon                                  East Leake
     dioxide emissions by more than 80% per load and                                             Loughborough
     cutting more than 1.17million lorry miles each year.                                        Leicestershire, LE12 6HX
                                                                                    Telephone:   0115 945 1996
                                                                                    Facsimile:   0115 945 1924
                                                                                    Email:       joanne.doxey@bpb.com
     How are benefits delivered?                                                    Website:     www.british-gypsum.com
     The service has improved delivery reliability for British
     Gypsum and its customers at a time when road transport
     is under increasing pressure as a result of road congestion,
     escalating fuel costs and the impact of the Working Time
     Directive, which is further restricting haulier flexibility.




27                              innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




Dulux Trade from AkzoNobel
Dulux Trade Ecosure
Developed by Dulux Trade in conjunction with leading sustainability
specialists Forum for the Future, the water-based Ecosure range of
paints offers the perfect balance of both proven sustainability and
market leading performance. Ecosure differentiates itself from the
competition by symbolising an approach to sustainability that is
grounded in scientific rigour, delivering demonstrable environmental
improvements whilst maintaining the highest performance standards.

Ecosure Matt offers performance that matches and in some cases
exceeds that of equivalent matt emulsions, delivering favourably
comparable levels of opacity and coverage, spreading up to
17m2. Available in the complete Dulux Trade colour range.

Ecosure Gloss and Undercoat deliver all of the advantages of water-
based systems and achieve a professional finish normally associated
with the solvent-based variant, being durable, quick drying and
providing good opacity and adhesion. The system will spread to
up to 16m2 and is available in the full Dulux Trade Colour range.




     What is innovative or new?                                                              Contact details
     Dulux Trade has used the Environmental Impact Analyser,                                 Contact:     Nicolas Guichard
     which measures the environmental impact of a product                                    Address:     Dulux Trade
     from extraction of its raw materials to the point it leaves                                          Wexham Road
     the factory, to reduce the embodied carbon and the VOCs                                              Slough
     of the Ecosure range. Ecosure’s cans are made of minimum                                             Berkshire
     25% recycled material.                                                                               SL2 5DS
                                                                                             Telephone:   0870 242 1100
                                                                                             Email:       duluxtrade_advice@ici.com
                                                                                             Website:     www.duluxtrade.co.uk/ecosure
     How are benefits delivered?
     The embodied carbon in Ecosure Matt has been reduced
     by 25% and by 30% in the Ecosure Gloss and Undercoat
     system compared to standard Dulux Trade formulations, which
     means a reduced impact on the environment. The VOCs have
     also been reduced by 49% in Ecosure Matt, 78% in Ecosure
     Gloss and 84% in Ecosure Undercoat which helps reduce
     low level ozone and photochemical smogs. Ecosure paints
     perform as well as the standard Dulux Trade formulation.
     *Gloss and Undercoat reductions are compared with Dulux Trade solvent-based
     variants as the market is over 85% solvent-based and 98% for gloss specifically.




28                                       innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
energy & carbon saving




Hanson UK
Recycled Cold Mix Asphalt
A 90 per cent recycled, low energy asphalt, which is mixed cold,
has been developed by Hanson and bitumen suppliers Nynas.

Asphalt is normally produced at high temperatures in an energy-
intensive process and can contain up to 25 per cent recycled
material. Northamptonshire Highways – a partnership between
Atkins and Northants County Council – recognised the potential
to reduce carbon emissions and increase recycling by introducing
a cold mix product. Hanson and Nynas were tasked to develop
the asphalt, which is made by mixing road planings with Nyrec, an
emulsion bitumen binder specially designed for cold production.

Full scale trials have been undertaken and initial feedback has
been very positive.




     What is innovative or new?                                                     Contact details
     It contains up to 90 per cent recycled asphalt and can                         Contact:     David Weeks
     be used as a surface course. Normal asphalt mixes                              Address:     Hanson
     contain only around 25 per cent of road planings.                                           The Ridge
                                                                                                 Chipping Sodbury
                                                                                                 Bristol
                                                                                                 BS37 6AY
     How are benefits delivered?                                                    Telephone:   01454 316000
                                                                                    Facsimile:   01454 325161
     The product maximises the recycling of worn-out
                                                                                    Email:       david.weeks@hanson.com
     roads, reduces carbon emissions due to the low
                                                                                    Website:     www.hanson.com/uk
     energy mixing process, reduces energy consumption
     and creates a safer working environment because
     operatives are not exposed to hot materials.




29                              innovation & achievement 2008 (electonic version)                                    construction products association
innovation & achievement 2008
energy & carbon saving




Kingspan Insulated Panels
Kingspan EnergiPanel
EnergiPanel is an insulated solar air heating system designed for roof
and wall applications as a supplement to the main heating system.
It comprises a modified version of the Kingspan KS1000 FC Box
Profile PIR composite panel and so is fitted as an integral part of the
cladding system - the only additional work needed is to fit internal
plenums containing the fans, the air grills at the base of the panel
and cavity closers above the extraction point. EnergiPanel is suitable
for a range of applications and can be easily incorporated with
conventional HVAC systems. The product has been on the market
for less than six months, but has already been installed on several
big sheds, with a school and an office building forthcoming. Data
collected so far shows that the product has the potential to reduce
a building’s heating requirements and therefore costs, by up to 20%.




     What is innovative or new?                                                     Contact details
     By using the building envelope to collect and distribute heat,                 Contact:     Phil Smith
     EnergiPanel helps to potentially reduce carbon emissions                       Address:     Kingspan Insulated Panels
     through lower fuel consumption. Because it uses an integral                                 Greenfield Business Park No2
     part of the building and is not an “add-on”, there is minimal                               Greenfield
     demand on the design process, build time and materials used.                                Holywell
                                                                                                 Flintshire, CH8 7GJ
                                                                                    Telephone:   01352 716100
                                                                                    Facsimile:   01352 710161
     How are benefits delivered?                                                    Email:       phil.smith@kingspanpanels.com
                                                                                    Website:     www.kingspanpanels.com
     Profiled hollows beneath the crowns allow air to move up
     through the panel whilst it is warmed by the simple process
     of using the outer steel skin as a solar energy absorber.
     Thermostats control low energy fans which distribute heat
     accordingly throughout the building. 890m² of EnergiPanel
     was installed on one project, with modelling data showing
     that it would provide 556kWh of energy over the year,
     equivalent to saving 142 tonnes of carbon dioxide annually.




30                              innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




LB Plastics Limited
Sheerframe HED
The Sheerframe HED window brings together new thermal
and production technologies to deliver a super-insulating
window for high-performance applications. Sheerframe HED
windows with a U-Value of 0.8 W/m2K are proven to help
meet up to level 5 and 6 of the Code for Sustainable Homes
and therefore help to make zero carbon homes a reality today.
Accredited by the BSI to the British Fenestration Rating Council’s
Domestic Window Energy Rating scheme, the Sheerframe HED
window is proven to be, by a considerable margin, the most
thermally efficient accredited window available in the UK.

Uniquely, this high level of performance is achieved with a
conventionally styled outward opening casement featuring slim
sightlines and is available in white, woodgrain or any RAL colour.

Sheerframe HED windows are available with the
BS7950 security Kitemark to meet the requirements
of Secured by Design and therefore collect more
credits within The Code for Sustainable Homes.


     What is innovative or new?                                                     Contact details
     Sheerframe HED incorporates a revolutionary new glazing                        Contact:     Mike Butterick
     system which ‘integrates’ the glass into the structure of                      Address:     LB Plastics Limited
     the window frame. In addition, the system incorporates                                      Firs Works
     new insulated frame profiles and new ‘Thermlock’                                            Nether Heage
     reinforcements which are manufactured using re-cycled                                       Derbyshire
     PVC window waste. Other production innovations reduce                                       DE56 2JJ
     the carbon footprint of the manufacturing process.                             Telephone:   01773 852 311
                                                                                    Facsimile:   01773 857 080
                                                                                    Email:       mike.butterick@lbplastics.co.uk
                                                                                    Website:     www.litchfield-group.co.uk
     How are benefits delivered?
     The superior thermal and security performance of Sheerframe
     HED windows enables house builders to comply with higher
     ratings within The Code for Sustainable Homes. Significantly,
     Sheerframe HED windows are available through existing
     regional fabricators and installers making their use practical,
     convenient and cost-effective for the developer.

     Given the conventional styling of Sheerframe HED windows, they
     can be used as replacement windows in order to significantly
     reduce the carbon footprint of the UK’s existing housing stock.




31                              innovation & achievement 2008 (electonic version)                                        construction products association
innovation & achievement 2008
energy & carbon saving




Marshalls plc
Reduction in
Compressed Air
Compressed air is relied heavily on for the press shed at Marshalls
which contains six wet presses with each press having a cylindrical
tank fitted with two ventures to create a vacuum. The true cost
of this was valued in line with the aim to reduce energy and
carbon emissions, and it was noted that there was a discharge
of 48 tonnes of C02 and electricity costs of £8,422.62 per annum.

Based upon the results, alternative methods could be implemented
and Marshalls invested in using liquid ring pump system for generating
vacuum by using a motor pump unit which could drive two presses
from one pump assembly. This meant that out of six presses, one
unit would supply vacuum to two presses, each pump unit assembly
was driven by a 5.5 kilowatt motor and came as a complete
assembly with motor, pump, liquid gas separator and mounting
plate. The unit was also configured to give partial water recycling.




     What is innovative or new?                                                     Contact details
     Converting from compressed air which required very little                      Contact:     Ron Short
     capital outlay, but with high running costs to alternative                     Address:     Marshalls plc
     systems saves on energy sources, carbon emissions and                                       Dollar Industrial Estate
     running costs and pay back on capital outlay in a very short                                Falkirk
     space of time making alternative methods more sustainable.                                  FK2 7YS
                                                                                    Telephone:   01324 614900
                                                                                    Facsimile:   01324 614949
                                                                                    Email:       ron.short@marshalls.co.uk
     How are benefits delivered?                                                    Website:     www.marshalls.co.uk
     Carbon emissions were reduced to 38 tonnes per annum and
     a saving on electricity of £2903.93 per annum by introducing
     the pumps. The unit was also configured to give partial
     recycling which meant that the only added water would be
     to cover evaporation losses, a reduction in energy from
     27kw/h to 16.5kw/h.




32                              innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
energy & carbon saving




ABM Bridge Systems
RENAULT F1 TEAM CFD
CENTRE, ENSTONE
The application of pre-engineered segmental arches in bridge
construction is well established in Europe, Ireland and increasingly
accepted in the UK. This form of construction can speed programme
time substantially. However application of these civil engineering
structures as a green alternative to conventional building is unique
in the UK. An intensive 12 week casting programme was required
to produce all the elements for the building which has a 16.l4 metre
span, 6.5 metre height and a total length of 62.5 meters. Comprising
of 25 rings of 2.5 metre length in 75 cast elements weighing up to 32
tonnes each. Elements were shipped to site sequentially and
construction began.The new building is to house a world-class computing
facility that will be used to perfect the aerodynamics of the 2009
series cars. Once waterproofed, backfilled, earthed over and landscaped
the green mound would have minimal visual impact. Additionally, the
earth sheltered building will provide a stable thermal environment
requiring less energy input for cooling and heating than conventional
structures by utilising the thermal mass of the precast structure.


     What is innovative or new?                                                      Contact details
     A unique and innovative use of buried, pre-cast,                                Contact:     Roger Morgan
     ground interactive structure to form a high profile,                            Address:     ABM Bridge Systems
     environmentally friendly and cost effective research                                         Ollerton Road
     building. Use of this type of application as a green                                         Tuxford
     alternative is unique in the United Kingdom.                                                 Nottinghamshire
                                                                                                  NG22 0PQ
                                                                                     Telephone:   01777 872233
                                                                                     Facsimile:   01777 872772
     How are benefits delivered?
                                                                                     Email:       roger.morgan@abmeurope.com
     An energy efficient environmentally friendly building. Savings                  Website:     www.abmeurope.com
     in terms of construction time, the construction process
     of the primary shell was carried out in six working days.
     Minimal visual impact on the surrounding area. Natural
     daylight enters the building through circular cut outs
     forming light wells and a glass wall curtain on one side.




33                               innovation & achievement 2008 (electonic version)                                   construction products association
innovation & achievement 2008
energy & carbon saving




Aggregate Industries
Sustainability
Since we began to monitor and report on our CO2 emissions
in 2002, we were aware that asphalt production was the most
significant component of our company’s carbon footprint. As
a hot process it consumes energy to dry and heat aggregates
and to maintain the bitumen at the right temperature.

In 2007, Haughmond Hill in Shropshire became our testbed
plant where we tested various means to improve the efficiency
of fuel use and by doing so reduced CO2 emissions. This place
was chosen because of its better-than average performance
and close material supply connection being located within
a quarry. This pilot has recognised that it is vital to consider
the entire process, from the supply, delivery and storage
of raw materials to the technologies adopted from
other industries.




     What is innovative or new?                                                     Contact details
     Specialists from Metso Automation have worked                                  Contact:     Delia Shannon
     closely with us on this project, bringing with them                            Address:     Aggregate Industries
     expertise from other sectors. The outcomes will                                             Bardon Hall
     shape the future of how asphalt is produced while                                           Copt Oak Road
     creating less environmental impact in terms of the                                          Markfield
     amount of fuel used for every tonne of product.                                             Leicestershire, LE67 9PJ
                                                                                    Telephone:   01530 816664
                                                                                    Facsimile:   01530 816666
     How are benefits delivered?                                                    Email:       delia.shannon@aggregate.com
                                                                                    Website:     www.aggregate.com
     Already the improvements have saved 10% of the fuel
     used previously. In examining the entire process we have
     been able to deliver improvements not just to CO2
     emmissions but to other parts of the process as well.




34                              innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
energy & carbon saving




Celotex
Celotex XR3200
Celotex XR3200 is a rigid PIR insulation board. The product is
manufactured in a continuous stream by pouring the chemical
between two pieces of aluminium foil which is then passed
through an oven to stimulate the chemical reaction and cell
structure formation. Once produced the product is cut to
size and allowed to cure for approximately 48 hours.




     What is innovative or new?                                                       Contact details
     Celotex XR3200 represents the thickest PIR insulation                            Address:     Celotex
     offered by any manufacturer of such products. This provides a                                 Lady Lane Industrial Estate
     unique position to Celotex in UK and international markets.                                   Hadleigh
                                                                                                   Ipswich
                                                                                                   Suffolk
                                                                                                   IP7 6BA
     How are benefits delivered?
                                                                                      Telephone:   01473 822093
     Celotex XR3200 offers the opportunity to help                                    Facsimile:   01473 820880
     realise the demand for carbon reduction through                                  Website:     www.celotex.co.uk
     improved energy efficiency due to its insulation
     value created by its unique thickness.

     The new product is aimed at cut to fit applications
     between rafters and joists as well as floors. It provides
     the installer with ability to utilise single layer systems,
     saving time, money and indeed on-site handling and
     waste when compared to double layer systems.




35                                innovation & achievement 2008 (electonic version)                                        construction products association
innovation & achievement 2008
energy & carbon saving in Action
                      Colorcoat                                ®




                                                                                                                                                                                       cra
                                                                      Sustainability                                                                                                   Co
                                                                                                                                                                                       en
                                                                                                                                                                                       ma
Corus Colors  Case study                                                                                                                                                               Arc

Confidex Sustain®
              Bulmers                                                                                                                                                                  All
                                                                                                                                                                                       of
                                               Annerville, Clonmel,                                                                                                                    wit
                                                                                                                                                                                       the
                                         Tipperary
Confidex Sustain® offers the first CarbonNeutral building envelope                                                                                                                     we
                                                                                                                                                                                       allo
in the world measuring and offsetting its impact from cradle to cradle
                                         Project: Bottling Hall                                                                                                                        suc
i.e. manufacture through to installation, use and end of life, reuse,                                                                                                                  4.
                                         Architects: John M Allen Architect                                                                                                            co
recycling or disposal. This means for every 1kg of CO2 emitted by the
                                         Main contractors: Sisk & Mulcahy                                                                                                              Eu
                                          insulation,
pre-finished steel, cladding, fixings andConstruction Corus will off-set                                                                                                               thi
                                                                                                                                                                                       Eu
1kg in climate friendly projects overseas. These have a social as well
                                         Cladding contractors:                                                                                                                         co
                                         Corus investing in renewable
as environmental benefit and will see Paddy Wall & Sons - Phase 1.                                                                                                                     co
                                         Gleeson Roofing N. Ireland - Phase 2                                                                                                          of
energy and energy efficiency projects in various locations worldwide.                                                                                                                  rec
                                               Profiler/Supplier: Euroclad (Ireland),
                                               Eurobond                                                                                                                                Ro
                                                                                                                                                                                       so
Confidex Sustain® offers a zero carbon building envelope
                                       Profile reference: 0.7 32/1000 profiled
                                       top sheet with 32/1000 liner
system. It goes beyond considering just one element of the (roof),                                                                                                                     He
                                       Europanel Extra 125mm and Firemaster
cladding system to assess and off-set all parts including the                                                                                                                          Eu
                                       Extra 75 mm & 150mm (wall).
                                                                                                                                                                                       15
internal and external pre-finished steel cladding sheets, fixings                                                                                                                      pe
                                                                                                                                                                                       req
and insulation. Confidex Sustain® is available when a Colorcoat
                                       Colorcoat product: Colorcoat
                                                           ®


                                       HPS200 in Meadowland and Moorland
                                                       ®                                                                                                                               the
                                        pre-finished steel product
HPS200 Ultra or Colorcoat Prisma Green (walls); Merlin Grey (roof)
         ®                            ®
                                                                                                                                                                                       sp
                                                                                                                                                                                       Eu
is used as part of a Colorcoat® assessed cladding system.
                                                                                                                                                                                       we
                                                                                                                                                                                       sys
                                                                                                                                                                                       fro
                                               Meadowland            Moorland Green                                                                                                    pre
                                                                                                                                                                                       Co


                                                                                                                                                                                       “W
     What is innovative or new? Grey
                              Merlin
                                                                                                 Contact details                                                                        C
                                                                                                                                                                                        It
     Using Life Cycle Assessment data for each part of the                                      Contact:           Stephen Fisher                                                       t
     cladding system, Corus can accurately identify how much                                    Address:           Corus Colors
                                         Evergreen Bulmers                                                                                                                              e
     gas that contributes to global warming has been emitted at                                                    Shotton Works                                                        J
                                         The production of cider has been an outstanding success           Stag, Linden Village and Strongbow, a £50 million expansion
     each stage of the process from manufacture and installation, more than doubling its
                                         story in Ireland over the last decade,
                                                                                                                   Deeside
                                                                                                           plan is underway at Annerville in Clonmel. Working to a                     Pe
     to use and end of life, reuse, recycling orshare, largely at the expense of beer. Leading that
                                         market disposal.                                                          Flintshire, CH5 2NH
                                                                                                           masterplan designed by architects H J Lyons & UK                            exp
                                         success story is Bulmers of Clonmel, Co. Tipperary. The Irish     Engineering Services, around half of that investment has been               pa
                                                                                                Telephone:
                                         Bulmers is part of the C&C Group Plc, one of Ireland’s leading
                                                                                                                   01244 892405
                                                                                                           spent on three new state-of-the-art bottling halls each housing             the
                                         drinks companies, whose cider is marketed as Magners   Facsimile: a bottling process with a capacity of 50,000 bottles per hour.
                                                                                                                   01244 810336                                                        co
                                         outside Ireland. To meet the current and anticipated future                                                                                   wit
                                                                                                Email:             stephen.fisher@corusgroup.com
     How are benefits delivered? for the company’s cider brands which include
                                         demand                                                            Apart from its success in the Irish drinks market, Bulmers can              ba
                                                                                                Website: now claim that its new building benefits from the world’s first
                                         Bulmers Original Irish Cider, Magners Original Irish Cider, Ritz,         www.colorcoat-online.com                                            of
     Confidex Sustain® tangibly demonstrates the construction                                                                                                                          Col
     supply chain’s commitment to sustainability by specifying
     the first CarbonNeutral building envelope in the world.                               www.colorcoat-online.com


     Provides peace of mind for the supply chain in the
     specification of the most sustainable pre-finished
     steel products and cladding systems available. These
     will deliver long-term building envelope solutions
     with the ultimate levels of performance.

     Provides an important source of differentiation
     for designers and building owners as more people
     select climate friendly brands and products.

     Assesses the environmental impact of the pre-finished steel
     cladding system from cradle to cradle. Covers the whole
     pre-finished steel cladding system, not just one element.

36                                    innovation & achievement 2008 (electonic version)                                                            construction products association
innovation & achievement 2008
energy & carbon saving




H + H UK Limited
Compressors Project
- Pollington
Our survey highlighted that three variable speed compressors used
at the site, although modern efficient units, would benefit from the
installation of a central governor which would innovatively monitor,
survey and log the compressed air network data; this was to ensure
the system works properly and highlights any possible energy savings.

The installed governor has improved operating efficiency
and reduced energy usage and associated emissions of
CO2 by 93 tonnes annually. There has also been an annual
saving of £9,500 in reduced energy usage and £4,500 from
the service contract due to reduced running hours.

The governor is web-enabled and connected to H + H UK’s
network allowing running details and efficiencies to be interrogated
from any PC. This will assist in highlighting additional opportunities
for energy savings and our commitment to reducing CO2 emissions.




     What is innovative or new?                                                     Contact details
     Data logging of compressor running times and efficiencies                      Contact:     Dr C B Cook
     is an innovative approach and will highlight opportunities                     Address:     H + H UK Limited
     for saving energy and reducing CO2 emissions.                                               Celcon House
                                                                                                 Ightham
                                                                                                 Sevenoaks
     How are benefits delivered?                                                                 Kent, TN15 9HZ
                                                                                    Telephone:   01732 886333
     The installation of the governor has reduced operating                         Facsimile:   01732 886810
     costs and the environmental impacts associated with                            Email:       colin.cook@hhcelcon.co.uk
     CO2 emissions. The techniques used have a direct                               Website:     www.celcon.co.uk
     applicability for other precasters who use multiple
     air compressor systems with respect to reducing
     their operating costs and energy consumption.




37                              innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




Hanson Formpave
Water Recycling &
Geothermal Heating
The recycling and reuse of rainwater, using permeable paving as
the reservoir for storage, shows great potential in the reduction
of mains water consumption for low grade uses. Water for
toilet flushing, landscaping and car washing can be harvested
within the pavement structure and pumped out for re-use.

Hanson Formpave has constructed a field site at BRE that
incorporates the Aquaflow system but also the rainwater recycling
and Ground Source Heat Pump (GSHP). The paving structure
provides more than 50% of the mains water for non-potable
uses and when full, supplies a family of four with 30 days of water
without any extra rainfall. The GSHP is linked to underfloor
heating and cooling system and provides 6kw to moderate and
maintain the temperature. With this combined system, 80%
of domestic heating and cooling costs can be removed and
payback on the system is usually achieved after 3-6 years.




     What is innovative or new?                                                      Contact details
     Integration of Aquaflow with GSHP technology delivers                           Contact:     Steve Spikes
     a unique and innovative sustainable method of harvesting                        Address:     Hanson Formpave
     rainwater and managing floodwater, providing an energy                                       Tufthorn Avenue
     efficient benefit through a heat/cooling solution to the interior.                           Coleford
     Offering a variety of applications within the industry both in                               Gloucestershire
     the commercial/domestic sectors allowing Hanson Formpave                                     GL16 8PR
     to partner geothermal experts and companies in extending                        Telephone:   01594 836999
     the reach of this solution to the construction industry.                        Facsimile:   01594 810577
                                                                                     Email:       steve.spikes@formpave.co.uk
                                                                                     Website:     www.hanson.co.uk/formpave
     How are benefits delivered?
     Aquaflow permeable paving has a storage capacity of
     approx 1,000 litres per 10m2 of paving, yielding a possible
     5m3 of water in a medium to large sized driveway. 80% of
     domestic heating and cooling costs can be removed using
     this system. Payback is achieved within 3-6 years. Is an
     attractive combined onsite rainwater harvesting package
     based on multiple environmental and end-uer benefits
     within one system whilst minimising any additional costs
     for installation, a practical solution to water management.




38                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




Lister Trade Frames Limited
Elitis Energy A+ Windows
Elitis Energy A+ Windows are the result of close
collaboration with our key suppliers to produce a glazing
option that would provide the best energy performance
coupled with the highest security requirements.

Combining specialist framing and glazing components developed
with our supplier partners, the Elitis A+ Window has been certified
by the British Fenestration Ratings Council (BFRC) as achieving
an ‘A3’ energy efficiency. ‘A’ is the highest energy efficiency rating
on a scale where ‘G’ is the poorest. Most double glazed windows
in the UK would only achieve an ‘E’ rating at the moment.

After consulting our customer base, we decided to combine
the highest level of window security testing on this product
achieving British Standards BS7950 and ACPO’s Secured by
Design approval to be able to offer the industry’s first window
to combining these to exceptional elements. Customers have
sold hundreds of this industry leading product since its launch.




     What is innovative or new?                                                      Contact details
     It achieves the highest energy efficiency rating for windows,                   Contact:     Mark Warren
     reducing the overall energy loss from the product to zero.                      Address:     Lister Trade Frames Limited
     This is achieved by balancing the energy retained within                                     Unit 2 Govan Road
     the property with the solar gain into the property.                                          Fenton Industrial Estate
                                                                                                  Stoke on Trent
     Achieving an ‘A3’ rating, Elitis A+ products                                                 Staffs, ST4 2RS
     actually contribute energy into the home.                                       Telephone:   07808 364731
                                                                                     Facsimile:   01782 391916
                                                                                     Email:       mark.warren@listertf.co.uk
                                                                                     Website:     www.listertf.co.uk
     How are benefits delivered?
     Reducing carbon emissions is the number one goal on the
     world’s agenda. In the UK, of all energy usage, domestic
     properties are responsible for 27% of CO2 emissions. Some
     25% of that energy is lost through poorly insulated windows.

     Installation of the highest energy efficient Elitis Energy
     A+ windows makes a huge reduction to a homes wasted
     energy, reducing carbon emissions and fuel costs.

     Adding the highest security also reduces
     the unwanted loss of valuables.




39                               innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
energy & carbon saving




Marley Eternit
Energy Management &
Employee Awareness
Marley Eternit aim was to reduce its electricity consumption per
tonne of product by 10%, in line with their 14001 accredited
Environmental Management System. A software solution called
EIServer was used to give live information to key site management
so continual checks could be made.With advice from the Carbon
Trust, initially raising awareness of factory and office personnel
and then revamping factory lighting by introducing sensors which
detect motion, as no staff were present large areas of production
didn’t require lighting. Lighting was also changed and replaced
with a low energy usage bulbs which reduce CO2 emissions. The
project amounted to £6,500, however the operational savings
were more than £9,000 per year. Improvements from the bulbs
resulted in a 50% reduction in the number of burning hours, a
halving in the circuit load and an increase in lamp life from 8,000
hours to 20,000+ hours. The project enabled them to reach the
corporate environmental objective of a 10% reduction of electricity.




     What is innovative or new?                                                      Contact details
     With the software installation of EIServer, live information                    Contact:     Roy Faunch
     was given to key site management and therefore                                  Address:     Marley Eternit
     continual checks could be made on electrical usage.                                          Lichfield Road
                                                                                                  Branston
                                                                                                  Burton upon Trent
                                                                                                  Staffs, DE14 3HD
     How are benefits delivered?
                                                                                     Telephone:   01283 722222
     The correct energy management with the installation of                          Facsimile:   01283 722242
     Optilux HB4 to replace the high pressure Sodium lighting, with                  Email:       royfaunch@marleyeternit.co.uk
     a massive cost saving on some applications of 70% on running                    Website:     www.marleyeternit.co.uk
     costs. Specially engineered reflectors used to maximise
     lighting levels. Daylight LUX sensitive and occupancy sensors
     installed maximising energy savings. The lighting is of good
     quality and a smaller amount of fittings were required because
     of the increased quality of lighting. Lastly, briefing sessions
     with factory and office personnel with a sticker and poster
     campaign was introduced to help raise awareness levels.




40                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




Marshalls plc
Block Plant Compressed
Air Management
After evaluation and the success in our Flag and Kerb plant,
Marshalls Block plant installed a variable speed compressor
in order to save on costs and also reduce carbon emissions
which was capable of matching the peak demands of the plant.
With the use of an ultrasonic leak detector all air leakage was
eliminated then data loggers were fitted to the compressor and
data was collected for the demand of air which was required.

The compressor was fitted with a new discharge air ducting
system. The compressor was sited by a duct whereby in the
summer months, the heat from the compressor would blow
out of the building, and the winter months would allow the
heat to warm the factory by way of a summer/winter ducting
system which we could divert to the exterior and interior.




     What is innovative or new?                                                     Contact details
     Although the cost of a brand new compressor was                                Contact:     Ron Short
     £29,000 a number of elements had to be taken into                              Address:     Marshalls plc
     consideration, to fit the wrong type of compressor would                                    Dollar Industrial Estate
     have pushed up running costs and resulted in needless                                       Falkirk
     carbon emissions. The plant demands are monitored                                           FK2 7YS
     and logged and it was because of the plant fluctuations                        Telephone:   01324 614900
     that a variable speed compressor was chosen as the                             Facsimile:   01324 614949
     best solution as it matches the energy input to the plant                      Email:       ron.short@marshalls.co.uk
     demands by speeding up and slowing down as necessary.                          Website:     www.marshalls.co.uk




     How are benefits delivered?
     Clear monitoring of the plant demands and using a
     variable speed compressor to deal with the fluctuations
     by speeding up or slowing down the motor to suit,
     results in reduction of input energy, reducing carbon
     emmisions and unlike a fixed displacement machine, it
     can make cost saving which will quite easily pay back the
     capital outlay over a realitively short period of time.




41                              innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
energy & carbon saving




Marshalls plc
Sustainability and Carbon
Impact Reduction
Through constant research, developments and implementation,
Marshalls have been able to produce products intended
for long life with low maintenance. This has been identified
as a very low risk of pollution and in majority of cases, can
be easily recycled. More than 10% of Marshalls’ incoming
aggregate stream is comprised of recycled materials.

Marshalls is committed to reducing its CO2 production output
by working with the BRE and in partnership with the Carbon
Trust to calculate the embodied emissions of its domestic
product range and reduce product carbon emissions.

In addition to a committed reduction in CO2, Marshalls is
also supplying eco-friendly concrete block paving which has
a 39% smaller carbon footprint. An online carbon calculator
has also been launched enabling users to measure the
CO2 impact of Marshalls hard landscaping products.


     What is innovative or new?                                                       Contact details
     Marshalls Carbon Calculator has been specially developed                         Contact:     Chris Harrop
     using products life cycle information that has been                              Address:     Marshalls plc
     independently verified. This means that all of the CO2                                        Landscape House
     emitted during production of raw materials, manufacture and                                   Lowfields Business Park
     transportation of the product has been carefully measured                                     Elland
     and minimised and is available to consumers online at                                         HX5 9HT
     www.marshalls.co.uk/sustainability for ease of information also the              Telephone:   01422 312000
     carbon labelling of its products is informative to the industry.                 Facsimile:   01422 312999
                                                                                      Email:       chris.harrop@marshalls.co.uk
                                                                                      Website:     www.marshalls.co.uk

     How are benefits delivered?
     Lower carbon footprint, eco-friendly paving and the delivery
     of information. Marshalls use of the standards developed by
     the Carbon Trust to calculate the embodied carbon emissions
     of its domestic product range and reduce product carbon
     emissions. Its commitment to carbon labelling allow gardeners,
     designers and builders alike to be informed about the
     products they are buying.




42                                innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
energy & carbon saving




Redland
Redland Solar Water
Heating System
This flat plate solar water heating system integrates directly
with the pitched roof, as a cost-effective micro-renewable
energy solution for new housing. It reduces energy
consumption, helps reduce harmful CO2 emissions and
reduces bills in a design that sits unobtrusively flush within the
roof, instead of appearing like a bolted on afterthought.




     What is innovative or new?                                                        Contact details
     The Redland Solar Water Heating System is designed to                             Contact:     Redland Marketing Department
     integrate unobtrusively with traditional roof tiles, instead                      Address:     Monier Ltd
     of being mounted on top. As well as providing an aesthetic                                     Sussex Manor Business Park
     advantage for what is the most proven micro-renewable                                          Gatwick Road
     technology, this system’s integrated design means a higher                                     Crawley
     standard of weathertightness and stability against wind uplift.                                West Sussex RH10 9NZ
     As part of a total new roof, installed with the recommended                       Telephone:   01293 618418
     fixings, the system is uniquely backed for weathertightness                       Facsimile:   01293 614548
     by the Redland 15-year Roof System Guarantee.                                     Email:       roofing.redland@monier.com
                                                                                       Website:     www.redland.co.uk


     How are benefits delivered?
     The Redland Solar Water Heating System is a cost-
     effective renewable energy solution with a 4m2
     collector area to provide up to 70% of an average
     three bedroom household’s typical hot water needs.

     It is easy to install for the contractors.

     Once in place, the system is ready for connection to
     the domestic water storage tank via a pump station.
     Sensors between the collector and tank link to a
     control panel to regulate safe temperatures.




43                                 innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
energy & carbon saving




SIG PLC
eviee
eviee is a specialist distribution company supplying the most
comprehensive range of sustainable building products contained
within the fabric of a building. We offer the customer impartial
expertise across our entire product portfolio, ensuring that they
install the right solution to fulfilling their particular needs.
Utilising predominantly web based communication;
eviee offers clients the most direct route for sourcing
contemporary and proven construction products.

From floors to roofs, ceilings to walls, windows to doors,
grey water systems to rain water harvesting. Our product
portfolio is combined with our ability to supply information
regarding the most up to the minute legislation and innovative
developments in sustainable construction products. This ensures
that eviee is able to offer a complete single source solution.




     What is innovative or new?                                                      Contact details
     Our approach is our innovation. At eviee we take a sustainable                  Contact:     Paul Roche
     view as opposed to a purest environmental view. As a result                     Address:     SIG PLC
     our solutions are practical and commercially viable for the                                  SIGnet House
     client, offering tangible environmental and fiscal benefits which                            17 Europa View
     may be readily incorporated into construction projects.                                      Sheffield
                                                                                                  S9 1XH
                                                                                     Telephone:   0845 8738612 / 07703 104849
                                                                                     Facsimile:   0114 285 6456
     How are benefits delivered?
                                                                                     Email:       paulroche@eviee.com
     eviee provides an easily accessible single source for                           Website:     www.eviee.co.uk
     sustainable products and services. Our online presence
     is underpinned by a team of specialist who are able to
     discuss a customer’s specific needs and advise them of
     the appropriate practical solution from a contemporary
     range of leading brand products. This often involves the
     development of a tailored solution marrying more than
     one supply partner. eviee makes it easy for customers to
     identify, compare, choose and install the right solution.




44                               innovation & achievement 2008 (electonic version)                                    construction products association
innovation & achievement 2008
energy & carbon saving




Tarmac Topblock
Online Code for
Sustainable Homes
In December 2006 the government launched the Code for
Sustainable Homes in a drive to provide sustainable homes
and reduce Carbon Dioxide emissions. As a major supplier to
the housing market, our aim is to provide reliable advice on
Building Regulations, construction best practice and innovations
in the use of concrete masonry for walls and floors. An online
seminar was chosen to communicate with the customers.

The seminar consisted of two presentations followed by a live
question and answer session. The first presentation discussed
the benefits of concrete and masonry construction in housing
in providing thermal mass to even out internal temperature
variations and avoid summer overheating. The second presented
the background and some simple theoretical case studies for
meeting the Code requirements. The Q&A session allowed live
interaction between the presenters and the online audience.




     What is innovative or new?                                                     Contact details
     The seminar was publicised in advance via postal and                           Contact:     Trevor Grounds
     electronic mail to customers and website visitors and via                      Address:     Tarmac Building Products
     direct communication from sales staff. Questions could                                      Millfields Road
     be sent both before and during the seminar and the                                          Ettingshall
     presentations were available to download afterwards.                                        West Midlands
     There were 263 participants online during the seminar                                       WV4 6JP
     at an average time of 49 minutes for the 50 minute                             Telephone:   01908 585993
     event. Many times that number have since viewed the                            Facsimile:   01908 585958
     website and a DVD has been distributed widely.                                 Email:       trevor.grounds@tarmac.co.uk
                                                                                    Website:     www.tarmac.co.uk


     How are benefits delivered?
     An efficient way to communicate to a large number of
     people both on the day and via subsequent viewing on the
     website. Reduced carbon footprint as participants were
     based in their office and homes and no travel was involved.
     Continued access to the seminar and ability to post questions.
     An opportunity to get early feedback on the industry’s
     understanding of the Code and their requirements for
     further advice. The success of this seminar has opened the
     potential for repeat events across the range of developing
     legislation and best practice for sustainable construction and
     promote benefits of concrete and masonry construction.




45                              innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
energy & carbon saving




Wolseley
Wolseley Sustainable
Building Center
Built at a cost of £3.2 million, the 6,800 sq ft Wolseley Sustainable
Building Center (SBC) in Leamington Spa aims to accelerate the UK
building industry’s move to embrace sustainable construction. A living,
interactive centre for decision-makers throughout the construction
industry, the SBC showcases many of Wolseley UK’s 7,000 sustainable
products across 13 areas: drainage and water conservation; sub
structure; wall and floor construction; roofing; wall finishes; flooring;
windows and doors; renewable technologies; heating and ventilation;
lighting; bathrooms and toilets; miscellaneous; and timber.

Importantly this is a practical aid to architects, designers and
builders; all products featured are available to the UK industry
today, through Wolseley’s nationwide 1,800 branch network.
The SBC is already attracting great interest from some of the
UK’s leading developers and property companies. Even before
its official opening, more than 140 visits to the Center had
been scheduled by customers and other interested groups.


     What is innovative or new?                                                    Contact details
     The Wolseley SBC is unique - the first commercial                             Contact:     Tim Pollard
     showcase in the UK for sustainable building products                          Address:     Wolseley UK
     and materials. Many of the products featured are                                           Spa Park
     new to the UK market, and the SBC also holds a                                             Leamington Spa
     database of detailed information on the performance                                        CV31 3HH
     characteristics of different manufacturers’ products.                         Telephone:   01926 705569
                                                                                   Email:       tim.pollard@wolseley.co.uk
                                                                                   Website:     www.wolseleysbc.co.uk
     How are benefits delivered?
     The Sustainable Building Center has attracted widespread
     media coverage and generated interest form across the wider
     construction industry. More than 140 organisations have
     already booked SBC visits. The SBC is already stimulating
     increased sales of energy and carbon saving products
     including insulation, PV, solar thermal, recycled aggregates,
     biomass, CHP, ASHP and rainwater harvesting technologies.




46                             innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
energy & carbon saving




Worcester, Bosch Group
Greensource Air to
Water Heat Pump
The Greensource air to water heat pump is the latest renewable
technology from Worcester, designed to provide a complete
heating and hot water solution for domestic properties. The
technology inside an air to water heat pump works on similar
principles to a domestic fridge. An external fan draws air from
outside the building into the unit before converting the latent heat
within the air into useable heat for home. Designed to work with
existing wet central heating systems, Greensource air to water
heat pumps transfer the converted heat into water to deliver
low-cost, energy saving heating and hot water all year round.




     What is innovative or new?                                                    Contact details
     Greensource air to water units have a COP (Coefficient                        Contact:     Jason Hartley / Jo McCarthy
     of Performance) of up to 4 so they can produce up                             Address:     Willoughby PR
     to four times more heat energy for use in the home                                         Calthorpe Road,
     than the electrical energy they consume, generating                                        Birmingham
     approximately 4kW of heat energy for every kW used.                                        B15 1TS
                                                                                   Telephone:   0121 456 3004
                                                                                   Facsimile:   0121 456 9300
                                                                                   Email:       jasonh@willoughby-pr.co.uk
     How are benefits delivered?
                                                                                                jom@willoughby-pr.co.uk
     Air source heat pumps work by converting the energy                           Website:     www.worcester-bosch.co.uk
     of the air outside into heat, creating a comfortable
     temperature inside the house as well as supplying
     energy for the hot water system. As with all heat pumps,
     air source models are most efficient when supplying
     low temperature systems such as underfloor heating
     but can also be used with oversized radiators.




47                             innovation & achievement 2008 (electonic version)                                       construction products association
innovation & achievement 2008
improvements in site efficiency
The construction industry is constantly looking        With improvements in site efficiency the industry
for ways to deliver the completed building or          has delivered a range of solutions that have
construction project in shorter time, by using fewer   responded to the need for best value rather
resources and offering better value for money.         than lowest price. Driven by market forces
Improving site efficiency is a key part of this.       these improvements can reduce the need
                                                       for regulation, but also encourage clients and
Certainly manufacturers who can show that their        specifiers to procure best value products.
products will help improve efficiency have an
added opportunity to gain a competitive edge.
innovation & achievement 2008
improvements in site efficiency




Ancon Building Products
Ancon Lockable Dowel
Dowels transfer load across joints in concrete. At
expansion/contraction joints they are used with a sleeve
to allow movement. Ancon’s new Lockable Dowel was
developed for use at temporary movement joints, most
commonly constructed in post-tensioned slabs.

It allows initial shrinkage of the concrete to take place and
then, after a pre-determined period (generally 60-120 days),
when movement has stabilised and the joint has been filled,
the dowel is locked in position. The locked dowel continues to
transfer vertical load, but movement can no longer take place.

The system comprises a dowel, a sleeve component, a
locking plate and a can of Ancon epoxy resin. The dowel is
manufactured in Duplex stainless steel; one end has a series
of grooves to accept the locking plate. The stainless steel sleeve
is fitted with a plastic L-shaped box which allows the resin
to be poured into the sleeve from the top of the slab.




     What is innovative or new?                                                    Contact details
     The Ancon Lockable Dowel is unique; no other product enables                  Contact:     Annabelle Wilson
     a dowel to be locked after an initial phase of movement and is                Address:     Ancon Building Products
     capable of transferring a comparable shear load.                                           President Way
                                                                                                President Park
     In the past, solutions were developed on site by combining                                 Sheffield
     a range of available products: Conventional rebars inside                                  S4 7UR
     debonding sleeves, locked with resin pumped through tubes.                    Telephone:   0114 275 5224
     However, any misalignment would restrict movement and                         Facsimile:   0114 276 8543
     with load transfer at a minimum, a corbel support would                       Email:       awilson@ancon.co.uk
     be required.                                                                  Website:     www.ancon.co.uk




     How are benefits delivered?
        • A complete, engineered solution
        • Supplied as a system
        • More effective at allowing movement in the
          initial phase than a debonded rebar
        • The box-section allows lateral, longitudinal and
          some rotational movement to occur initially
        • More effective at transferring load. No requirement
          for a corbel support so the joint is easier to detail
          and construct, and less materials are used
        • Does not require the formwork to be drilled.




50                             innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
improvements in site efficiency




CEMEX UK
Viadeck
In 2006, building materials provider, CEMEX UK developed a ground
breaking new asphalt product - Viadeck, in response to the ever
growing challenges caused by deep carriageway reconstruction.
Viadeck is a proprietary asphalt that combines all the benefits
of multi-layer road surfacing systems in a single layer laid up to
120mm thick and at temparatures up to 20 degrees celsius lower
than traditional asphalt. This means it reduces overall project
surfacing time through a single application, thus minimising costly
and annoying road closures and traffic management measures.

Developed at CEMEX’s National Technical Centre in Sotham,
Warwickshire Viadeck can be used in thicknessess ranging from
60mm to 120mm. It may be used as either a thick surface
course or replacement for two existing asphalt layers.




     What is innovative or new?                                                      Contact details
     Viadeck makes it possible to completely reconstruct a                           Contact:     Marit Meyer-Bell
     section of carriageway during a limited working window.                         Address:     CEMEX House
     It can be laid up to 50% quicker than traditional multi-layers                               Coldharbour Lane
     asphalt road surfacing systems, thus reducing congestion and                                 Thorpe
     emissions from slow moving traffic. As it is applied in a single                             Egham
     layer Viadeck can be also laid at slightly lower temperatures                                Surrey, TW20 8TD
     and is applied in one pass using a conventional road paving                     Telephone:   01932 583208
     machine, thus saving further fuel, emissions and time.                          Facsimile:   01932 583224
                                                                                     Email:       marit.meyerbell@cemex.com
                                                                                     Website:     www.cemex.co.uk

     How are benefits delivered?
     Viadeck has been used successfully on the M6 and the
     Ray Hall Viaduct, north-west of Birmingham. In both projects
     CEMEX took possession of the road at 10pm and completed
     the application in readiness for the motorways to re-open at 6am.

     At Ray Hall, this saved vital time and disruption to
     approximately 230,000 vehicles. The carbon footprint of the
     works was reduced by approximately 95% compared with a
     conventional solution, mostly due to the fuel saved from the
     traffic jams that were avoided.




51                               innovation & achievement 2008 (electonic version)                                    construction products association
innovation & achievement 2008
improvements in site efficiency




Charcon
Road-Pod
The Road-Pod is a sustainable precast concrete modular system for
use as traffic and Pedestrian Refuge Islands (patent applied for).

The design takes into consideration the Road Traffic Act and the
Design Manual for Roads and Bridges.

The Road-Pod system is available in a range of sizes to suit the
various applications. There are five types of arrangement, from
1.2 m to 1.8 m in width and a number of island combinations.
Other widths are available on a made to order basis.

The units come complete with provision for illuminated or
reflective type bollards, solar powered bollards, high level
and solar powered columns, cast-in tactile surfaces and lifting
points. The weight ranges from 382 kg to 1.93 tonnes.




     What is innovative or new?                                                      Contact details
     Road-Pod is a total off-site solution that reduces the                          Contact:     James Gadher
     number of components from fifteen to three.                                     Address:     Charcon
                                                                                                  Marions way
     A typical unit can be installed over a period of three                                       Coventry Road
     to eight hours, with minimum traffic management,                                             Croft
     compared to two to three days with traditional on-site                                       Leicestershire, LE9 3GP
     methods using kerbs, in-situ concrete and asphalt.                              Telephone:   01455 288275
                                                                                     Facsimile:   01455 285284
                                                                                     Email:       charconspecialist@aggregate.com
                                                                                     Website:     www.charconspecialist.com
     How are benefits delivered?
     Charcon’s Road-Pod offers a very cost effective off-site
     sustainable solution, with significant savings on cost and
     installation time. Additional benefits include reduction of site
     time spent in danger and enhancement of pedestrian safety.
     The ease and speed of installation of Charcon’s Road-Pod
     dramatically cuts road closure times, meaning that congestion
     and the increased CO2 production of stopping and starting
     traffic is greatly reduced.




52                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
improvements in site efficiency




Knauf Drywall
Brio Dry Floor
Knauf Brio is a new gypsum fibreboard for use as a dry floor
screed. In place of wet screeds, it is an interlocking board with
precision engineered lapped edges for easy fitting. Brio Dry Floor
Screed boards are laid so simply it is a case of placing a board
down, running a bead of Brio Joint Adhesive (with its innovative
applicator) down the lower edge, placing a second board down
so the edges meet, and screwing the two together using Knauf
Brio Screws. Installed and ready for traffic in a fraction of the
time of traditional wet screeds, Brio is exceptionally lightweight
whilst still providing a tough, impact resistant surface. Thermally
transparent and with highly efficient heat dispersal, Brio is ideal
for underfloor heating systems and the wood fibre backed
Knauf Brio WF provides excellent impact sound reduction.




     What is innovative or new?                                                      Contact details
     The quality and accuracy of boards, due to a unique                             Contact:     Mark Crowsley
     production process, means a superb quality of finished                          Address:     Knauf Drywall
     floor can be achieved as a fast, dry process without skilled                                 PO Box 133
     labour. Messy materials and machinery are no longer                                          Sittingbourne
     required. Weight per m² and environmental credentials                                        Kent
     are greatly improved over traditional techniques.                                            ME10 3HW
                                                                                     Telephone:   07918905350 / 01795424499
                                                                                     Facsimile:   08704601443
                                                                                     Email:       info@knauf.co.uk
     How are benefits delivered?                                                     Website:     www.knaufdrywall.co.uk
         • Replaces wet screed - no more messy
           materials and machines onsite
         • Ready for traffic in minutes – no setting/drying out time
         • Reduced weight decreases the impact on structure
           – high-rise buildings require less structural engineering
           due to large volumes of concrete removed
         • Simple installation – reduced labour costs
           and added value for drylining companies
           (can now offer walls, ceiling and floors)
         • Thermally transparent – highly efficient
           transference from underfloor heating systems
           – even heat dispersal and minimal heat loss.




53                               innovation & achievement 2008 (electonic version)                                   construction products association
innovation & achievement 2008
improvements in site efficiency




Milton Pipes Limited
Quickchange Moveable
Barriers (QMB)
The QMB is a precast temporary barrier system designed to
allow safe, rapid lane changes even at peak traffic flows. The basic
principle is that the units are able to be moved in an unbroken
chain by a bespoke vehicle at speeds of up to 10mph, allowing
rapid change in the work areas, or reversing the lane numbers
in traffic tidal flow systems around traffic flow patterns at major
road works. The system comprises a linked “chain” of reactive
tension barrier units which can be slightly raised from the road and
moved across the carriageway by the Transfer Vehicle allowing lane
priority changes during road works and for Traffic Tidal Flows.

Milton Precast is manufacturing the QMB units at its
Sittingbourne facility using moulds supplied by its American
client, Barrier Systems Inc. The complete system, including the
Barrier Transfer Vehicle, will then be leased to The Highways
Agency by another Kent company, Highway Care which
is Barrier Systems exclusive distributor for the UK.


     What is innovative or new?                                                      Contact details
     The QMB is being used to place temporary concrete barriers                      Contact:     John West
     where traffic lanes need to be closed quickly. The barrier                      Address:     Milton Pipes Limited
     transfer vehicle moves the units across the carriageway                                      Cooks Lane
     allowing lane priority changes. All this can be achieved with                                Sittingbourne
     a considerable increase in safety as all movement is done                                    Kent
     simply, by driving the vehicle along the chain of units.                                     ME10 2QF
                                                                                     Telephone:   01795 425191
                                                                                     Facsimile:   01795 478232
                                                                                     Email:       jw@miltonprecast.com
     How are benefits delivered?                                                     Website:     www.miltonprecast.com
     The system allows better phasing of road works and more
     intensive construction. Improving productivity and better
     utilisation of manpower and plant, therefore workforces
     are not exposed to the dangers of passing traffic whilst
     making the changes. It is a rapid, safe means of carrying out
     lane changes in high traffic areas. Allows increased traffic
     flows during peak periods, increased work area during off
     peak periods, so allowing projects to be completed in a
     shorter time, with less disruption to traffic at peak periods.




54                               innovation & achievement 2008 (electonic version)                                        construction products association
innovation & achievement 2008
improvements in site efficiency




Polypipe Building Products
Polysoak
Polysoak is an instant soakaway system that has been designed to
save the installer time and money. The new unit comprises of two
Polystorm Cells (PSM1) which are clipped together and wrapped
in a geo-textile, to prevent the ingress of silt and debris, providing
quicker installation. The unit is then covered in a protective bag, to
guard the geo-textile from UV rays, during storage and transit.

Benefits of Polysoak:
   • Pre-constructed soakaway unit suitable for
      draining roof areas of up to 25m2
   • More efficient than traditional granular fill soak-aways
   • Lightweight, quick and easy to install
   • Ideal for shallow excavation
   • Reduces preparation, cartaway, backfill and installation times
   • BBA approved
   • 95% void ratio ensuring maximum water storage capability.

This lightweight system improves on site process efficiency and
provides a tailored solution to single plot water management.


     What is innovative or new?                                                      Contact details
     Only pre-constructed soak-away on the market. Is up to                          Contact:     Brian Stannett
     three times more efficient than its traditionally constructed                   Address:     Polypipe Building Products
     equivalent. Reduces the use of aggregates on site. Provides                                  Broomhouse Lane
     an effective on plot water management solution.                                              Edlington
                                                                                                  Doncaster
                                                                                                  South Yorkshire, DN12 1ES
                                                                                     Telephone:   01709 770000
     How are benefits delivered?                                                     Facsimile:   01709 770001
     Puts storm water collected from roofs and run-off areas                         Email:       brian.stannett@polypipe.com
     straight back into the natural water table (suitable for draining               Website:     www.polypipe.com
     areas of up to 25m2). Easy for merchants to stock, handle and
     deliver. Easy for installers to order, collect and install. More
     efficient than traditional granular fill soak-away with 95% void
     ratio ensuring maximum water storage capability. Lightweight,
     quick and easy to install, ideal for shallow excavation, reduces
     preparation, cart away and backfill and installation times.




55                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
improvements in site efficiency




Aggregate Industries
Pedestrian & Traffic
Segregation -
Ashington Site
Ashington Site experienced a dramatic increase in both
vehicular and pedestrian movements, relating to collection
and delivery of finished goods/products, forklift truck activities,
private vehicle movements and contractors visits to site.

The yard was extended allowing a single file, one-way traffic
system to be implemented and HGV holding area with a
private car park. Walkways were mapped out providing safe
access and egress to all production facilities on site from the
car park/reception area. A 10 mph site speed limited was
imposed and signage installed. New Health and Safety leaflets
with relavant information, along with a location map showing
the one way system has been designed for use on site.




     What is innovative or new?                                                      Contact details
     Risk assessments highlighted the likelihood of an incident                      Contact:     Sean Butler
     occurring on site (contact with moving machinery)                               Address:     Aggregate Industries
     was increasing. It became apparent that there was                                            Brock Lane
     a need to improve the sites layout with regard to                                            West Sleekburn
     the segregation of pedestrians and vehicles and the                                          Bedlington
     management of FLT’s and HGV movements on site.                                               NE22 7BY
                                                                                     Telephone:   01670 53438
                                                                                     Facsimile:   01670 53475
     How are benefits delivered?                                                     Email:       sean.butler@aggregate.com
                                                                                     Website:     www.aggregate.com
     The management team developed an ideal layout of the site,
     taking into consideration health and safety, environmental
     impact and lean manufacturing methodologies. This meant
     re-locating finished goods stock, also taking into consideration
     the reduction of vehicle movements, double handling
     products and reduce vehicle turnaround times when
     loading/unloading vehicles with finished goods, whilst at the
     same time removing hazards associated with these activities.




56                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
improvements in site efficiency




Dow Building Solutions
INSTA-STIKTM
Multi-Purpose Fast Cure
INSTA-STIK MP is a polyurethane foam in gun format for
Dry Lining applications, developed to adhere a range of
boards to an array of construction surfaces, and cutting out
need for primary mechanical fixings or drywall adhesive.

The product was designed to be as flexible and easy to use
as possible on construction sites, with the ability to be applied
horizontally to floors or vertically to walls. The adhesive
can be applied directly to the substrate, and can be strictly
controlled through the trigger and screw, meaning less waste.

Further efficiencies come from the fact that boards can be applied
to a surface in just 3-5 minutes, and finishing can take place within
the hour – not only that, it can also be used on wet surfaces (with
moisture even improving the curing time), and its minimal expansion
formula means gaps can be filled without boards being pushed out.




     What is innovative or new?                                                      Contact details
     Using PU foam as an adhesive is a breakthrough – it                             Contact:     Alexander Crisp
     eliminates the need for water in Dry Lining applications,                       Address:     Dow Building Solutions
     and has a low expansion formula meaning it can be used to                                    Diamond House
     fill small gaps post application, without the expansion seen                                 Kingsbury Crescent
     from other materials that can lead to ‘buckling’ of boards.                                  Staines
                                                                                                  Middlesex, TW18 3AG
                                                                                     Telephone:   07971200481
                                                                                     Facsimile:   02031394013
     How are benefits delivered?
                                                                                     Email:       acrisp@dow.com
     • Health and safety - minimum noise and vibration;                              Website:     www.dowbuildingsolutions.com
       freedom from solvents and HCFCs.
     • Ease of use - simple handling, easy cleaning, no dust/
       debris, low weight and fast, accurate application.
     • Efficiency - no need for electricity/water,
       minimal preparation and clean up time, ability for
       finishing trades to complete more quickly.
     • Coverage – one 750ml can equivalent
       to 25kg bag of drywall adhesive.
     • Performance – good tensile strength, no substrate
       damage and no thermal bridging or visible fasteners.




57                               innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
improvements in site efficiency




Redland
Rapid Vented Ridge
Universal System
A mechanical-fix ventilating ridge tile system for pitched
roofing that is compatible with Redland half round and angle
ridge tiles and with all the popular Redland slates and tiles. Its
flexible seal simplifies bringing the advantages of dry-fix to
more complex roof designs across a site throughout the supply
chain. Therefore merchants and contractors benefit alike.




     What is innovative or new?                                                      Contact details
     Instead of architects, specifiers or contractors having to                      Contact:     Redland Marketing Department
     apply a specific system with specially shaped seals for each                    Address:     Monier Ltd
     type of slate or tile product across different roofs on a                                    Sussex Manor Business Park
     multi-unit site, the Rapid Vented Ridge Universal System is                                  Gatwick Road
     compatible with all Redland’s slates and tiles for both half                                 Crawley
     round and angle ridge tiles. Merchants and contractors benefit                               West Sussex RH10 9NZ
     from only having to stock one product instead of two as                         Telephone:   01293 618418
     previously – reducing stock, inventory and part numbers.                        Facsimile:   01293 614548
                                                                                     Email:       roofing.redland@monier.com
                                                                                     Website:     www.redland.co.uk
     How are benefits delivered?
     • Takes a third less time than wet mortar to install. Requiring
       no mortar, the system incurs less risk of wastage whenever
       adverse weather creates prolonged downtime.
     • It eliminates typical problems of a mortar’s
       inadequate sand quality or incorrect mix ratio.
     • Better performance against storm damage than
       mortar on completion and low maintenance,
       to benefit a client’s lifetime costings.
     • By integrating a ventilation function, the system
       simplifies the design and installation.
     • Creates an aesthetically tidier looking roof.
     • Unique wind tunnel tests during development
       ensured compliance with BS 5534 and BS 5250.



58                               innovation & achievement 2008 (electonic version)                                     construction products association
innovation & achievement 2008
improvements in site efficiency




Saint-Gobain Isover
Isover RD 35
Construction System
The Isover RD35 system is an acoustic party wall construction
engineered to achieve the highest credits through Robust Details,
under the Health and Wellbeing acoustic requirements of the Code
for Sustainable Homes (CfSH). RD35 allows housebuilders to retain
the preferred dry method of finish ensuring the most economical
solution available. Combined with a 100mm design cavity, Isover
RD35 glass wool acoustic slab gives a system that achieves minimum
50dB sound insulation in standard twin masonry leaf separating walls
with plasterboard dry lining - 5dB above Building Regulations and
qualifying for 3 CfSH credit points. Secured within the cavity using
standard insulation retaining wall ties, the Isover RD35 acoustic slab
comprises up to 80% recycled content and has a best in class A+
rating under the BRE Green Guide generic listing for glass wool,
whilst the construction should achieve at least a C rating. After
extensive site testing, Robust Details have approved the construction
as wall type E-WM-14 for use without pre-completion testing.




     What is innovative or new?                                                     Contact details
     The Isover RD35 system is the first masonry separating                         Contact:     Helen Tunnicliffe
     wall system to achieve Robust Detail approval and                              Address:     Saint-Gobain Isover
     three CSH credits without a wet parge coat finish.                                          Sales & Marketing Department
     Housebuilders can therefore meet Part E standards                                           Gotham Road
     using the traditional dry plasterboard on dabs finish,                                      East Leake, Loughborough
     without the need for additional wet trades on site.                                         Leics, LE12 6JU
                                                                                    Telephone:   0115 945 1145
                                                                                    Facsimile:   0115 945 1915
     How are benefits delivered?                                                    Email:       helen.tunnicliffe@saint-gobain.com
                                                                                    Website:     www.isover.co.uk
     The unique system allows housebuilders to claim the highest
     level of CSH credit currently achievable, giving valuable
     additional flexibility elsewhere in the house design. Cutting
     out the parge finish simplifies build scheduling by removing
     the need for additional wet trades, and reducing drying-out
     time, which has been estimated to cut both material costs
     and installation time by more than 20%, without introducing
     the uncertainty associated with pre-completion testing to
     guarantee Part E compliance.




59                              innovation & achievement 2008 (electonic version)                                        construction products association
innovation & achievement 2008
improvements in site efficiency




Saint-Gobain Isover UK
Climaver Plus R
Ductwork System
Climaver Plus R is a revolutionary all-in-one ductwork system
which is an alternative to traditional insulated sheet metal systems
for ventilation, air-conditioning and heating systems in buildings. It
is a high density, rigid glass mineral wool board, faced both sides
with a robust aluminium foil, with glass fibre mesh reinforcement
to the outer face for extra impact resistance and rigidity. Simple
reference guidelines facilitate cutting and construction, and a unique
male/female edge design allows precision airtight ducts to be
formed and installed more quickly than by the traditional method.

Climaver Plus R ducts provide a more efficient and economical,
easy clean, alternative to existing sheet metal duct systems, meeting
thermal, fire, and acoustic requirements for systems operating at
air speeds up to 18m/s and 800Pa pressure. Inherently quieter
and more energy efficient than insulated sheet metal systems,
Climaver is manufactured from glass mineral wool which uses
up to 80% recycled materials in the production process.


     What is innovative or new?                                                     Contact details
     The unique single piece construction enables rigid ductwork                    Contact:     Helen Tunnicliffe
     to be assembled and installed much more quickly, and at                        Address:     Saint-Gobain Isover UK
     lower cost, than equivalent insulated metal systems, whilst the                             Sales & Marketing Department
     inherent insulating properties of the structural mineral wool                               Gotham Road
     board provide benefits in lower noise operation, improved                                   East Leake, Loughborough
     thermal efficiency and an excellent sustainability rating.                                  Leics, LE12 6JU
                                                                                    Telephone:   0115 945 1145
                                                                                    Facsimile:   0115 945 1915
     How are benefits delivered?                                                    Email:       helen.tunnicliffe@saint-gobain.com
                                                                                    Website:     www.isover.co.uk
     It is quicker to assemble and install and more easily
     adaptable to on-site changes than sheet metal systems.
     Precision jointing and unique sealed edge design means low
     leakage rates, with associated energy savings. The inherent
     insulating properties make it around ten times more
     efficient at reducing system noise and four times more
     energy efficient than standard uninsulated metal systems.




60                              innovation & achievement 2008 (electonic version)                                        construction products association
innovation & achievement 2008
resource efficiency
The construction industry is one of the largest    its definition of ‘by-products’, which until recently
users of raw materials which when managed          has been determined by numerous case-laws.
effectively play a crucial role in ensuring the
sustainability of our built environment.           The Association is closely involved in delivering
                                                   greater opportunities to develop products
Many of the policies surrounding better resource   that address total life-cycle impact.
management are driven by the European
Union, which in recent years has published the     The examples highlighted this year again
Thematic Strategies for Waste Prevention and       demonstrate how manufacturers have either
Recycling and Resource Management. One of          replaced virgin materials with secondary
the key issues is the continuing revision of the   materials or ensured that manufacturing
Waste Framework Directive and in particular        and product use reduces the environmental
                                                   impact on the built environment.
innovation & achievement 2008
resource efficiency




Altro
Safety Floor
Recycling System
Until now it has been difficult to recycle safety flooring because
the abrasive nature of the aggregates, which give safety flooring its
signature slip resistance and durability. Altro has been working with
new technology which is able to break down manufacturing waste,
separate it into its component parts - aggregates, fibre and PVC - and
granulate it, to then be recycled into new safety flooring products.

Waste flooring is fed into a shredder, it then goes through a
series of screening tables where aggregate and fibrous materials
are recovered. The PVC material is then granulated, cleaned and
reduced in size. Currently, the aggregate is reused in new safety
flooring and the PVC chip is recycled into traffic cones, but by the
end of 2008 the company will use the recovered materials, along
with the PVC chip, in a range of recycled content safety flooring.




     What is innovative or new?                                                       Contact details
     This is truly a world first, as previously safety flooring had                   Contact:     Clare Schofield
     been viewed by many as impossible to recycle. Altro is now                       Address:     Altro
     developing this process further by creating the infrastructure                                Works Road
     for the reclamation of post-consumer waste which could be                                     Letchworth Garden City
     used to create new product, creating a ‘closed loop’ process                                  Herts
     for the manufacture of safety flooring.                                                       SG6 1NW
                                                                                      Telephone:   01462 489308
                                                                                      Facsimile:   01462 480010
                                                                                      Email:       csch@altro.com
     How are benefits delivered?                                                      Website:     www.altro.com
     The process will support Altro’s Six Steps to Sustainability
     launched earlier this year.The initiative is a series of commitments
     to manage Altro’s environmental and social impact. The
     recycling plant specifically helps meet the following objectives:
         • Create socially beneficial long-life products that can be
            disposed of safely
         • Effective management of production and post-
            installation waste
         • Minimising emissions through energy reduction
         • Diverting waste to landfill by effective reuse, reduction
            and recycling programmes.




63                                innovation & achievement 2008 (electonic version)                                     construction products association
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resource efficiency




ASSA ABLOY Door Solutions
ASSA CLIQ Electronic
Master Keying System
ASSA CLIQ electronic master key system provides the flexibility
of both electronic (CLIQ) and mechanical keys and cylinders in
the same system. It uses fewer raw materials in its build which
adds to it ease in manufacture. The electronic intelligence is
designed to give high security performance and to cope with future
developments. The electronic capabilities enable lost or stolen keys
to be easily removed from the system rather than replacing the
entire master key system; the keys can record the last 100 entries.

CLIQ cylinders maybe used on perimeter / high security doors
and CLIQ padlocks used to secure external gates; records
the last 1000 key entries. Mechanical cylinders can be used
on doors not requiring such extreme security or audit trailing.
ASSA CLIQ requires no cabling and can be easily installed
in the same way as a mechanical locking system, ensuring
cost effectiveness over the lifetime of the product.




     What is innovative or new?                                                      Contact details
     Timed audit trails maintain the integrity of the building.                      Contact:     Lorna Hylton
                                                                                     Address:     ASSA ABLOY Door Solutions
     Each CLIQ cylinder implements a blocking                                                     Unit 3-4, ZK Park
     element which prevents unauthorised access                                                   23 Commerce Way
     through a series of encryption codes.                                                        Croydon
                                                                                                  Surrey, CR0 4ZS
     Each CLIQ key allows controlled security by managing                            Telephone:   0208 688 5191
     the authorisation levels of groups / individuals; and adding                    Facsimile:   0208 688 0285
     proximity capabilities, it becomes even more multi-functional.                  Email:       lorna.hylton@assaabloy.co.uk
                                                                                     Website:     www.assa.co.uk / www.assaabloydoorsolutions.co.uk



     How are benefits delivered?
     ASSA CLIQ delivers a cost efficient system ensuring
     that high security is never compromised.

     Organisational changes no longer mean costly replacements
     as both the installed cylinders and keys can easily be
     reprogrammed; even after a security breach the keys can
     simply be cancelled. Staff or visitors within the organisation
     no longer receive more access than they actually require
     as all access rights are programmed directly onto the
     key. This master keying system is truly flexible.




64                               innovation & achievement 2008 (electonic version)                                       construction products association
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resource efficiency




Bradstone
Rainwater Harvesting
System
The Bradstone Rainwater Harvesting System is a revolutionary way
of collecting, storing and reusing rainwater which would normally go
to waste. The system is made out of recycled polypropylene and can
store up to 300 litres of water in each of its cylinders which are easy
to install in any home. The water can be used for toilets or watering
the garden – especially during the summer and the hose pipe ban.

The system allows home owners to be sustainable by
cutting down their water usage and at the same time
saving money. The water can be used for toilets or watering
– especially during the summer and the hose pipe ban.

There is also the added benefit that the collection of water
in homes will reduce the impact of flooding in the future
as excess rain water will be collected into the system.




     What is innovative or new?                                                     Contact details
     The whole system can be fitted within 500mm of the surface                     Contact:     Paul Wagstaff
     and can be installed by a competent DIY person rather than                     Address:     Bradstone
     an engineer. The storage modules come in two sizes and are                                  Hulland Ward
     made of 100% recycled polypropylene. Water passes through                                   Ashbourne
     the filtration system before being stored. To use, it can be                                Derbyshire
     pumped through the pump and sump unit connected to a                                        DE6 3ET
     hosepipe or a toilet cistern. Once hard or soft landscaping has                Telephone:   01335 372227
     been put in place, the system will be out of sight and requires                Facsimile:   01335 370973
     very little maintenance apart from cleaning out the filter.                    Email:       paul.wagstaff@aggregate.com
                                                                                    Website:     www.aggregate.com



     How are benefits delivered?
     By collecting rainwater from roofs, downpipes, patios and
     lawns, homeowners cut down on their water usage and save
     themselves money at the same time. The holding tanks are
     underground deprived of natural light so stagnation does not
     occur and odours are prevented by the constant flow
     of incoming and out flowing water. In contrast to some
     other systems that have proved to be hard to install
     and required a professional, Bradstone’s system is easy
     to install and is ideal for a competent DIY enthusiast (the
     only professional required is a registered electrician
     to connect the electricity supply to the pump).



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resource efficiency




Forticrete
Gemini Roof Tiles
The Gemini Roof Tile has been publicly recognised as a major
innovation since its introduction. However, several further
innovations in the product’s design, manufacture and packaging have
propelled the product forward enabling Forticrete to reach their
ideal, a true aesthetic alternative to the traditional clay plain tile.

Design changes were made that increased the strength of the tiles
at crucial areas, including the interlock, which was reduced in width
but increased in strength, affording another benefit as it reduced yet
further the number of tiles needed per square meter. In addition
new automated packaging techniques were introduced to enable
products to be “banded” in stacks of seven tiles, aiding security
during transport, creating secure cubes of shrink-wrapped palleted
product eliminating on-site wastage. Also, an additional designed-in
benefit has been in the process used for curing the product with
the installation of a new vapour curing process whereby vapour
is absorbed by the product during curing, locking in some 40% of
CO2 that would otherwise been released into the atmosphere.




     What is innovative or new?                                                       Contact details
     The production of a twin-tile aesthetic alternative to the                       Contact:     John Lambert
     clay plain tile. Through the creation of a multi-coloured                        Address:     Forticrete
     blend for each individual tile. Innovation has been achieved                                  Boss Avenue
     through two main routes – innovative pigment mixing                                           Off Grovebury Road
     technology that enables every tile to be colour blended                                       Leighton Buzzard
     creating a natural random effect and innovative pre-packaging                                 LU7 4SF
     technology through the use of robotic ‘pick-and-place’                           Telephone:   01525 244900
     racking following the curing process creating a totally random                   Facsimile:   01525 850432
     blend of colours in each product ‘band’ and eliminated the                       Email:       jlambert@forticrete.com
     need for mixing products from different pallets on-site.                         Website:     www.forticrete.co.uk




     How are benefits delivered?
     The new Gemini tile offers roofers a great compromise.
     It gives a plain clay tile effect, is less expensive and lays
     down to a lower rafter pitch, enabling it to be used
     on a wider variety of roofs. Increase in the strength of
     the tile, reduction of tiles per sq.metre, 7.5% less raw
     material is used in the production, packaging techniques
     were improved reducing on-site wastage and the curing
     process helped CO2 emissions from being released.




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resource efficiency




Profile 22 Systems Ltd
RCM – 100% Recycled
Reinforcement for
Windows & Doors
Recycled Composite Material (RCM) is a reinforcement for PVC-U
windows and doors. Supplied as a substitute to either steel or
aluminium sections, RCM is a cost effective alternative that offers
superb benefits, while being fully sustainable. Developed as part of
our proactive stance to increase the sustainable credentials of our
product range, RCM closes loop to the recycling process, offers
better thermal efficiency and has a minimum life cycle of 35 years.

RCM is a cost effective alternative offering superb benefits where the
anchorage of hardware is required in window and door outer frames
and casement window sashes. Using RCM means you can achieve a
better Window Energy Ratings (WER) over comparative windows
with steel or aluminium reinforcement, which have a greater heat loss.




     What is innovative or new?                                                     Contact details
     RCM is manufactured from first generation                                      Contact:     Andrew Reid
     post consumer waste PVC-U, so therefore                                        Address:     Profile 22 Systems Ltd
     made out of 100% recycled materials.                                                        Stafford Park 6
                                                                                                 Telford
     RCM is an excellent insulation material and has a                                           TF3 3AT
     thermal resistance value of - 0.17 w/mk. RCM is less                           Telephone:   07836 273933
     conductive than steel increasing thermal efficiency.                           Facsimile:   01952 290460
                                                                                    Email:       andrew.reid@profile22.co.uk
                                                                                    Website:     www.profile22.co.uk

     How are benefits delivered?
     • Unique and patent pending RCM
       reinforcement from Profile 22
     • 100% recycled composite material
       reinforcement – fully and easily recyclable
     • Increases thermal efficiency – achieves a higher energy rating
     • More than 35 years’ life expectancy
     • It doesn’t corrode or rust
     • RCM has a screw pull out value greater than steel
     • The price of RCM is stable
     • 20-30% increase in corner weld strength
     • User friendly, easy to cut and clean, lighter than
       steel - making it easier and safer to handle
     • RCM makes windows easier to install as it is lighter
       and windows can be carried more easily.


67                              innovation & achievement 2008 (electonic version)                                      construction products association
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resource efficiency




Tarmac Topblock
Take Back Scheme
During 2007 Tarmac Topblock launched a major initiative in
conjunction with HIPPOBAGS™. A scheme whereby customers
can purchase labelled 1m3 HIPPOBAGS™ into which broken
and off-cut blocks can be segregated. These filled bags are then
collected and transferred to the nearest Tarmac Recycling Limited
(TRL) depot plant for processing into recycled aggregate. A simple
cost effective scheme offering traceability of waste and certified
collection which assists with the audit trail for a Site Waste
Management Plan (the subject of potential legislation in 2008).




     What is innovative or new?                                                     Contact details
     The basis of the scheme is that Topblock customers can                         Contact:     John Teasdale
     take advantage of a service to remove and recycle their                                     Business Process Coordinator
     block waste through a very simple process of collection                                     Tarmac Building Products
     and delivery to Tarmac Recycling Limited depot or                              Telephone:   0845 606 2468
     Topblock plant for processing into recycled aggregate.                         Email:       john.teasdale@tarmac.co.uk
                                                                                    Website:     www.tarmac.co.uk



     How are benefits delivered?
     Waste recycled as an aggregate reduces the use of virgin
     aggregates and is both economical and environmentally
     friendly and a valuable contribution to government waste,
     recycling and landfill reduction targets for 2012 and 2015.
     This process being of benefit to both customers, suppliers
     and the company as a whole. Although the scheme is in its
     early stages a large amount of interest has been generated
     from customers, specifiers and Local Authorities.




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Aggregate Industries
Plastic Recycling
Waste plastic is recycled in specific cages provided by Flexible
Packaging/Recycling Limited. Once full, the cages are collected,
removing the need for a general waste skip and reducing land-
fill costs and skip hire. The recycled plastic is reused as pellets
for injection moulders. The cost saved is £5,000 per year.




     What is innovative or new?                                                      Contact details
     Using an external recycling company to collect and recycle                      Contact:     Pat Keating
     large mass plastic (122,535.00 plastic filter cloths) and after a               Address:     Aggregate Industries
     sample analysis was successful the trial was carried out at all                              The Crescent
     other sites reducing the large amounts of room needed to                                     Bardon Hill
     store this product.                                                                          Leicestershire
                                                                                                  LE6 1TS
                                                                                     Telephone:   01530 834351
                                                                                     Facsimile:   01530 838236
     How are benefits delivered?
                                                                                     Email:       pat.keating@aggregate.com
     One general waste skip had been removed from site which                         Website:     www.aggregate.com
     has resulted in a reduction in landfill, giving reduced skip hire
     and landfill costs. The recycled plastic is now made into pellets
     for injection moulders.




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resource efficiency




Aggregate Industries
Sustainability
Through Recycling
At North End, it was recognised that waste was becoming an
increasing problem in terms of disposal, cost and impact on the local
community and environment. As a result the site introduced a baler
to recycle waste plastic which would otherwise have been sent to
a landfill. The introduction of this scheme has seen the number of
skips being used cut by two thirds from 74 skips a year to 17. This
has reduced the cost of skip hire and tipping supplements to £5,221,
as opposed to £24,149 from the previous year. As well as cost
savings, the recycling has benefited the community and environment.
The local community now sees a reduction in vehicles using the
roadways by fifty seven transport movements per year, and recycled
material sold for manufacture of biodegradable refuse sacks or
damp proof course membranes and whose proceeds go to local
charities. We are also trialling a pilot scheme whereby employees
can recycle plastic from home using out facilities to encourage
employees and their families to generate less waste to landfill.




     What is innovative or new?                                                     Contact details
     For very little effort and with the minimal of costs of hiring                 Contact:     Steve Brown
     of a baler and a little organisation. Our company and the                      Address:     North End Works
     local community and charities have benefitted immeasurably                                  Ashton Keynes
     by reducing vehicle movement by fifty seven thus reducing                                   Swindon
     CO2 emissions by two thirds, reducing the amount of tonnes                                  Wiltshire
     to landfill dramatically and helping with long term landfill                                SN6 6QX
     issues. Providing charitable funding in the local community                    Telephone:   01285 646800
     and a cost saving of more than £18,000 to our company.                         Facsimile:   01285 646948
                                                                                    Email:       steve.brown@aggregate.com
                                                                                    Website:     www.aggregate.com

     How are benefits delivered?
     Environmentally, the benefits include the elimination of
     sending 24 tonnes of waste plastic each year to the landfill
     which reduces the landfill being filled with unnecessary
     waste. The process has been successful that it is being
     rolled out into other factories in the local area, and also
     encouraging families to recycle their household waste
     at the site. A significant cost saving to the business. Less
     vehicle movement and charities reaping the benefits of
     recycling this plastic waste being in the region of £3,500.




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Aggregate Industries
Recycle Water, Silt and
Energy Reduction
Kemnay ‘C’ – Measures to reduce energy and water consumption.

At Kemnay ‘C’ we use water for cooling saws and polishing machines
employed in the secondary processing of Fyfestone concrete blocks.
This water was obtained either from the mains supplies or by
pumping from a nearby quarry. To save energy it was decided to stop
pumping water from the quarry and to improve resource efficiency.
It was also decided to stop using water from the mains supplies.

In order to establish an alternative water supply, a holding pond
was built to hold process water from the factory and a pump
was installed to recycle water from the pond to the processing
machines. The holding pond was also interconnected to the
existing settlement pond system to maintain its functionality.




     What is innovative or new?                                                     Contact details
     We ceased using mains supply of water and in turn                              Contact:     Donald Keenan
     have eliminated water wastage by ceasing to return                             Address:     Fyfestone Master Block
     water to the quarry hole. Instead recycling water ponds                                     Aquithie Road
     have been built to accommodate excess water.                                                Kemnay
                                                                                                 Aberdeenshire
                                                                                                 AB51 5PD
                                                                                    Telephone:   01467 651026 / 07728 133939
     How are benefits delivered?
                                                                                    Facsimile:   01467 642342
     Eliminating the need to pump water from the quarry                             Email:       donald.keenan@aggregate.com
     saves £2,580 per month in electricity costs and                                Website:     www.aggregate.com
     generates an associated reduction in CO2 emissions.
     In addition, mains water usage has been eliminated
     from secondary processing activities. Health and Safety
     hazards have been removed from water cooling area.




71                              innovation & achievement 2008 (electonic version)                                    construction products association
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resource efficiency




British Gypsum
Thistle Durafinish
Thistle Durafinish, a gypsum finish plaster, is specially formulated to
provide increased resistance to accidental damage. Designed for
use in heavy traffic areas, Thistle Durafinish has been developed
for use in schools, hospitals, hotel and leisure, MOD, student
accommodation and some custodial projects. Suitable for new-
build projects and the refurbishment of existing walls, new Thistle
Durafinish enables significantly longer maintenance intervals
and lower long-term cost through improved durability in heavy
traffic areas. It is suitable for use on any boards, sound undercoats
(gypsum or cement-based) and many pre-existing backgrounds in
refurbishment situations. Thistle Durafinish is used to supplement
other wall protection solutions, such as barriers and laminate
sheeting, whose cost often prohibits their widespread use.




     What is innovative or new?                                                     Contact details
     Thistle Durafinish is unlike anything else available on the                    Contact:     British Gypsum
     market. It is designed to provide a cost effective, enhanced                   Address:     Drywall Academy Advice Centre
     durability solution, for areas where the cost of mechanical                                 East Leake
     protection cannot be justified. Unlike the expensive                                        Loughborough
     alternatives, it doesn’t require specialist application.                                    Leicestershire
                                                                                                 LE12 6JT
                                                                                    Telephone:   08705 456123
                                                                                    Facsimile:   08705 456356
     How are benefits delivered?
                                                                                    Email:       bgtechnical.enquiries@bpb.com
     Thistle Durafinish can be used on plasterboard or undercoat                    Website:     www.british-gypsum.com
     plasters for plastering, replastering and repair work on new-
     build or previously finished walls. The additional durability
     of Thistle Durafinish will reduced unplanned maintenance
     and extend planned maintenance intervals. By offering
     advanced protection from accidental damage in a wide range
     of situations and applications, Thistle Durafinish creates an
     environment conducive to educating, healing, living, working
     and playing without affecting the essential performance of the
     building elements.




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Marshalls Mono
Waste Reduction
To minimise environmental impacts from the operational life
cycle of our products and workplace. Reducing the consumption
of natural resources by creating less waste in the beginning and
recycling where possible to ensure less impact on landfill.

Seven waste streams were identified: Cardboard, Paper, Plastics,
Wood, Waste Colour Bags, Saw Department Slurry, Concrete
Waste (hardcore) and Energy Reduction. The first five of these
streams were entering the General Waste and as a result ending
up in landfill the remaining two streams had significant cost
attributed to removal from site. By segregating the streams each
area of waste was successfully targeted for reduction or recycling
on site. Secondary processing of plastics and colour bags was
contracted out to a local waste company, these were baled
onsite before transfer for further baling with the contractor’s
other waste. Wood, cardboard and paper were removed
from general waste streams by placing in skips and
removing through Biffa, thus reducing collections of general
compacted waste by Biffa from 18 to 10 per annum.


     What is innovative or new?                                                      Contact details
     By careful planning and employee participation a successful                     Contact:     Mark Everest
     management system was put into place. New screening deck was                    Address:     Marshalls Mono
     installed, the saw department slurry was mixed with farm manure                              Meadow Lane
     and spread on fields, saving £7,000 in disposal costs and plastics                           St Ives
     were removed and recycled and then used again on site.                                       Cambridge
                                                                                                  PE27 4LG
                                                                                     Telephone:   01480 308600
     How are benefits delivered?                                                     Facsimile:   01480 308610
                                                                                     Email:       mark.everest@marshalls.co.uk
     The aim was to double the recycled aggregate on site in                         Website:     www.marshalls.co.uk
     our Flag & Kerb by providing two grades of product 6mm
     – 0mm (dust) and 14mm to 7mm previously the concrete
     crusher could only screen 14mm to dust which limited
     the amount of recycled aggregate that could be used in
     product due to inconsistencies across the grade. Recycling
     on site through our own concrete crusher reduced the
     impact of aggregates by 13,000 tonnes and the hidden
     environmental impact of vehicle movements required to
     bring in aggregates and remove waste from site. Energy
     consumption was reduced by 8.7% in CO2 emissions,
     achieved by an energy team comprising of site management,
     maintenance electricians and fitters, yard personnel and
     site Health & Safety and Environmental specialists.




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Masterblock
Increased Transparent
Reporting of Recycled
Content Across Aggregate
Blocks Nationwide
Masterblock, a business within the Commercial Products Division
of Aggregate Industries, has raised the bar in the construction
industry with its commitment to guarantee that all its lightweight
aggregate blocks have a minimum recycled material content of 20%.

The basic minimum is 20%, but based on 2007 figures, can be
50% or more depending on the production area. Masterblock’s
manufacturing sites are spread across the United Kingdom, from
Melbur in Cornwall to Kemnay in Scotland giving the construction
industry a wide choice of sites from which to choose.

In many areas, the recycled content can be very high, depending
on local sourcing.



     What is innovative or new?                                                        Contact details
     The Masterlite range, which has always had one of the highest                     Contact:     Jeremy Lee / Mark O’Neill
     levels of recycled content of any lightweight aggregate block                     Address:     High Road
     on the market, now has a transparent recycled offering so the                                  Nether Kellet
     customer knows exactly what they are buying.                                                   Carnforth
                                                                                                    Lancashire
     A leaflet detailing the recycled content from specific factories is                            LA6 1EA
     available for download from www.masterblock.co.uk                                 Telephone:   01524 736636
                                                                                       Facsimile:   01524 736635
                                                                                       Email:       masterblock@aggregate.com
                                                                                       Website:     www.masterblock.co.uk
     How are benefits delivered?
     Masterblock consistently strive to be market leaders
     in sustainable construction. It is our mission to
     increase recycled content across our product range
     to build a sustainable future for tomorrow.

     The basic minimum is 20%, but based on 2007
     figures, can be more than 50% depending on the
     production area. Masterblock’s manufacturing
     sites are spread across the United Kingdom.




74                                 innovation & achievement 2008 (electonic version)                                     construction products association
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resource efficiency




Polypipe
Eco-Vat Home
Eco-Vat Home is a robust and cost-effective rainwater harvesting
system for the UK domestic market. Eco-Vat Home offers both
gravity-fed and pressurised systems. Within a gravity-fed system,
water is pumped from the Eco-Vat Home tank to a header
tank in the loft. The water is then fed to each appliance through
a gravity pipe system. Pressurised systems use a pump to feed
water directly to the appliance on-demand. Polypipe advise the
use of a gravity system where possible to reduce the effects of
pump failure in the event of a power cut. The range of Polypipe
Eco-Vat Home tanks has been researched and designed to meet
the exact requirements of the UK market, based on the national
average household water usage and the most up to date MET
office data. Eco-Vat Home tanks allow the homeowner to meet
their exact requirements and therefore provide the most cost
effective and efficient solution, without the need to over specify
and incur disproportionate purchasing and installation costs.




     What is innovative or new?                                                        Contact details
     No need for a concrete surround - Even in cases of a high water                   Contact:     Brian Stannett
     table all that is needed is a concrete base which the tank is                     Address:     Polypipe building Products
     strapped to.The structured wall design will withstand any ground                               Broomhouse Lane
     conditions. It provides a simple solution to the complex problem                               Edlington
     of rising water tables and changing weather patterns. As most                                  Doncaster
     systems are Installed during the summer months, when water                                     South Yorkshire DN121ES
     tables are at their lowest, the resulting winter rising water table is            Telephone:   01709 770000
     often not taken into account.Test have shown the tanks capability                 Facsimile:   01709 770001
     to withstand water pressure at a burial depth of up to six metres                 Email:       brian.stannett@polypipe.com
     or 0.6 bar, far beyond the pressure the tank is likely to face.                   Website:     www.polypipe.com




     How are benefits delivered?
     Pre-assembled ready for installation. No need for
     a concrete surround. In built leaf filter. Can be
     tailored to individual project needs; toilet flushing,
     washing machine use and garden irrigation.

     Reduces domestic mains water usage by 50%
     Reduces carbon footprint by lowering volumes of
     water from local treatment works. Provides a tailored
     solution to single plot water management.




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Profile 22 Systems Ltd
Post Consumer and Industrial
Waste PVC-U Windows &
Doors Recycling Service
Profile 22 work closely with its sister company, Dekura in offering
a dedicated post consumer window and door recycling service
that ensures the most economic and efficient recycling of PVC-U is
achieved. As a group company Epwin has invested several million
pounds to create the UK’s largest and most advanced PVC-U
recycling plant, capable of processing both post industrial and post
consumer PVC-U materials. Profile 22’s network of contractors all
operate a recycling programme for any old PVC-U products. Once
re-processed these PVC-materials are re-used into a wide range of
long-life building products. The replacement of old PVC-U windows
is gathering pace with 1.8m PVC-U window installations in 2006
being replacement. It is estimated by 2012 this will be in the region
of 3.9m frames*, hence the importance of promoting this service to
intercept this valuable material otherwise destined for landfill.
* Rigby market research




     What is innovative or new?                                                      Contact details
     This service enables old windows to be taken out and recycled                   Contact:     Andrew Reid
     into new windows, therefore cutting down the amount of virgin                   Address:     Profile 22 Systems Ltd
     material used in production of new windows.                                                  Stafford Park 6
                                                                                                  Telford
     Using our skills and processing capability our group has produced                            TF3 3AT
     the UK’s first window made from 100% post consumer waste.                       Telephone:   07836 273933
                                                                                     Facsimile:   01952 290460
                                                                                     Email:       andrew.reid@profile22.co.uk
     How are benefits delivered?                                                     Website:     www.profile22.co.uk

     How we deliver this service:
       • Stillage trolleys are made available on site to
         store the old windows ready for collection
       • Sophisticated material separation is undertake at Dekura
       • Recycle materials into pulverised or pellet compound
       • Materials are then reused

     Benefits of our service:
        • Our service intercepts 20,000 tons of valuable PVC-U
           material destined for landfill, if not recycled
        • Full post consumer waste and post
           industrial waste recycling
        • Full traceability




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Tarmac Precast Concrete
Recycling of Waste Materials
In 2007 the site reviewed its waste management system following
an increased demand for recycling and the increase in land fill taxes.
The site identified the need to separate waste streams; wood and
steel skips were introduced along with waste bins for plastics and
printer cartridges. A baling machine was sourced which is capable of
baling cardboard, office paper and plastic wrapping into 200kg bales
which are sold to recycling mills. Polystyrene cups have been replaced
by ceramic, alleviating this waste altogether. A crusher was hired to
break down scrap segments allowing both the concrete and steel
reinforcement to be recycled.




     What is innovative or new?                                                      Contact details
     The new changes that were made resulted in significant                          Contact:     David McLoughlin
     monetary savings, a reduction in traffic movement and therefore                 Address:     PO Box 1
     CO2 emissions were reduced, less skips were required to dispose                              Southwell Lane
     of waste and office recycling increased.                                                     Kirkby in Ashfield
                                                                                                  Nottingham
                                                                                                  NG17 8GQ
                                                                                     Telephone:   01623 688040
     How are benefits delivered?
                                                                                     Facsimile:   01623 688037
     Separation of waste materials and baling of paper products                      Email:       david.mcloughlin@tarmac.co.uk
     is now carried out on site. Landfill taxes, waste disposal and                  Website:     www.tarmac.co.uk
     transport costs have all been reduced. Polystyrene waste
     is no longer an issue and office recycling has improved.




77                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
resource efficiency




Hanson Building Products
Working Together to Reduce
Waste - Ipswich
Hanson operates three different business lines from its Ipswich
site all of which generate concrete waste material. The Premix
Plant and Floors and Precast plants waste is collected at the
Aggregate Blocks plant holding area and once there is enough
waste, a concrete crusher attends the site with a breaker to crush
and screen all the waste. This process is carried out every eight
to twelve months which results in all of the waste material being
processed back through the aggregate block batching plant to
produce a reclaimed aggregate Fenlite Block. Ready mixed lorry
waste is captured into a holding tank and put into the concrete
waste area and used for hard standing for storage or poured
into the designated waste area. Floor beams are manufactured
daily and cut using a diamond sawblade cooled with water, this
water is held in two holding tanks which capture the slurry as
well as rainwater and concrete waste generated is placed into
the waste area, production waste from the block press, the cuber
system and the pallet board turner is put into the waste area.


     What is innovative or new?                                                      Contact details
     In a joined up approach to waste minimisation the aggregate                     Contact:     Alan Harding
     block factory collects the waste from both the pre-mix concrete                 Address:     Hanson Building Products
     plant and the flooring plant and then has it crushed on a                                    Sproughton Road
     campaign basis to be used as a recycled aggregate.This approach                              Ipswich
     ensures that all virgin materials coming onto site leaves as a                               Suffolk
     finished product.                                                                            IP1 5AN
                                                                                     Telephone:   01473 461771
                                                                                     Facsimile:   01473 464117
     How are benefits delivered?                                                     Email:       alan.harding@hanson.com
                                                                                     Website:     www.hanson.biz
     Collaboration between ready mixed, precast and blocks units
     has ensured waste is contained with the works and there
     is no cross contamination as Ipswich is the first visit of the
     cleaners in the day and all areas are cleaned regularly including
     spillages from the conveyor belts, roads are swept weekly
     during summer and during winter bi-weekly this enables
     100% of waste to be recycled from waste generated on site.
     Logistics are easier and the site is a cleaner environment.




78                               innovation & achievement 2008 (electonic version)                                      construction products association
innovation & achievement 2008
resource efficiency




Bovis Lend Lease in conjunction
with 2K Manufacturing
RePlas Hoarding
RePlas Board is a new and innovative board product developed
to replace plywood, initially in temporary construction works
for site hoardings and concrete formwork and, potentially as a
finished material in the completed construction works. The board
is made using an innovative process called powder impression
moulding (PIM) recycling mixed waste plastics without the need
for expensive segregation of the plastics. The waste includes
many problematic plastic wastes such as those from waste
electrical and electronic equipment and responds to the aims
of five European Union Directives. When the product becomes
more widely used and further applications are developed, it
will reduce the volume of plastics being sent to land fill or for
incineration by replacing traditional construction materials and
reduce consumption of natural resources. RePlas board is currently
available in sheets of 2400x1000x19 millimetres weighing less
than 25kg with properties similar to plywood but more durable.




     What is innovative or new?                                                     Contact details
     The PIM process enables mixed waste plastic to be reformed into                Contact:     Matthew Locke
     a usable product without the need for expensive cleaning and                   Address:     Lend Lease Design
     segregation. Up to 20% non polymer content can be tolerated in                              142 Northolt Road
     the waste stream. No special tools are required. Boards can be                              Harrow
     prefinished in corporate colours, reducing labour costs.                                    Middlesex
                                                                                                 HA2 0EE
                                                                                    Telephone:   020 8271 8327
                                                                                    Facsimile:   020 8271 8295
     How are benefits delivered?
                                                                                    Email:       matthew.locke@lendlease.com
     • Uses a wide range of mixed plastics waste stream.                            Website:     www.bovislendlease.com
     • Reduces timber wasted in construction temporary works.
     • More durable than traditional timber hoarding available
       for painting or graffiti-resistant self-coloured finish.
     • RePlas Board can be recycled at least 10 times into new
       board. The manufacturer will give a 10% refund of purchase
       cost on returned boards, encouraging responsible recycling.
     • Lighter to handle than plywood.
     • Reduced risk of injury from timber splinters.




79                              innovation & achievement 2008 (electonic version)                                     construction products association
             26 Store Street
           London WC1E 7BT

            t. 020 7323 3770
            f. 020 7323 0307

  www.constructionproducts.org.uk




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