COMPREHENSIVE REFURBISHMENT OF EXTERIOR FACADE

Innovative adaption and re-development of a 40-year-old existing frame extends design life for a further 30 years whilst benefitting from spent embodied carbon.

PURPOSE OF THE WORK:

To completely overhaul curtain walling, glazing and pass-through doors to the new entrance and café extension and bring the whole building up to modern thermal standards with visually aesthetic appeal as befitting such an iconic landmark in the heart of Croydon.

WHAT WE DELIVERED:

As specialists in the remedial and renovation of existing glazed facades, we proposed to retain the original 1983 façade as opposed to the removal and replacement of this element or the full demolition of the site that had been considered through feasibility.

We wanted to reuse as much of the original aluminium curtain wall frame as possible, renovating to modern standards including replacement fire breaks of the original feature vertical columns. This bold plan meant huge amounts of embodied carbon could be saved, whilst making this building fit for another 30 years.

We were confident the thermal performance could be substantially improved through the design and development of a new thermal break and bespoke gaskets. The new glass specification had extended the glazing zone, so new glazing tables were also required to suit the new design.

The thermal performance of the façade was improved by an astonishing 62.5%, from 2.25W/m2K to 1.4W/m2K, which is comparable to a new build façade with current framing options; there is no deterioration in performance vs modern systems.

To achieve this, we developed a new thermal break, gaskets and supporting glazing table compatible to the existing framing whilst crucially increasing the glazing zone to incorporate a modern spec of glass. Whilst this results in the external façade line extending, multiple structural analysis determined the system could still support this weight. The new components were developed with our in-house 3D printing technology for prototyping, ahead of die cutting and extrusion of materials that we had confirmed as compatible. This meant minimal wastage in material, transport and energy through our development stage, and ensured our solution worked ‘first time right’.

BENEFITS:

• Acting as principal contractor, we co-ordinate the whole refurbishment
• Thermal performance of the façade improved from 2.25W/m2K to 1.4W/m2K
• Innovative approach saved over 1400 tC02 of embodied carbon
• Introduction of natural ventilation through vertical louvres enabled M&E engineers to specify a reduced HVAC system with localised Smart Controls and metering
• Replacing of over 1,000 units whilst building was occupied with minimal disruption and unparalleled tenant and resident communication
• This project symbolises the Retrofit campaign, in a landmark building which has been redeveloped to be a champion project, demonstrating how re-use can be more effective, responsible and desirable.