Knowledge Hub
Client: Manchester City Council and Far East Consortium
System: Intrastack Light-Gauge Steel Frame (LGSF)
Project Overview:
Intrastack Light-gauge steel frame (LGSF) from Saint-Gobain Off-Site Solutions, specified for the first phase of the Collyhurst Village regeneration project in Manchester, helped main contractor, DEX Construction Group Limited, construct the first block of 55 apartments in just 16 weeks – approximately half the time associated with a traditional concrete structure.
Regeneration Project
Manchester City Council and Far East Consortium (FEC) are working together to regenerate a large area of Manchester, running north of the city centre along the River Irk Valley. Known as Victoria North, it is the largest renewal project Manchester has ever seen.
The initial design for this first phase, comprising circa 100 apartments over three 5 and 6 storey blocks, used a traditional steel structure, but as Simon Adams, Managing Director at DEX Construction Group explains, this posed several limitations:
“The sheer size of the steel beams required would have impacted on the ceiling height in each apartment, plus we knew we would need some additional design time to be confident that we could meet the required standards for acoustic and fire performance. We considered using a concrete frame, but that would have meant starting on the design phase again, adding additional cost and time into the build.
“It was at this stage that we approached Intrastack to explore the benefits that a light gauge steel frame could deliver.”
A Complete Solution
Intrastack, as part of Saint-Gobain Off-Site Solutions, designed, manufactured & supplied the load-bearing structure, while sister companies, British Gypsum and Isover UK, supplied the system-tested and specified plasterboard, fire protection and insulation products for the site. This provided a seamless, end-to-end system, including full design, manufacture, and supply, with performance certification and warranties.
Simon Adams continues: “Compared to a concrete structure, the cost benefits of building with LGSF really stack up. For example, a tower crane and driver would have to be scheduled to lift each concrete floor section into place, typically at a cost of up to £3,000 per week, with an estimate of three weeks build-time per floor. In contrast, it has taken just 16 weeks to build the structure using Intrastack LGSF.
“This first phase of construction on the Collyhurst Village has gone to schedule, and our timescales have certainly been assisted greatly by the ease of working with Intrastack.
“We are likely to be working on this regeneration project for up to the next nine years and need supply chain partners that can help us to solve problems and be involved in the early stages of design. With the backing of the Saint-Gobain Group and the assurances that the system meets all required NHBC warranty and insurance approvals, Intrastack has quickly become a key partner to our business.”
Supporting the Local Community
Danny Johnson, Intrastack concludes: “The development of Collyhurst Village and South Collyhurst is built around a strategic regeneration plan, which places residents central to the decision making in how its community needs are met. A key part of this is to use local labour where feasible and a focus on building quality, affordable homes.
Our Intrastack manufacturing facility is based just a few miles away in Chorley and our local team have fully embraced the ethos of the project, helping to provide a safe and welcoming community and homes for those most in need in the North-West.”