ARCHITECTURAL SOLUTIONS PRECAST CONCRETE

WWW.TECHRETE.COM

PAGE PAGE 1. ABOUT TECHRETE 7. PRODUCTS - APPLIED

2. PLANNING & DESIGN 8. PRODUCTS - GRC

3. MANUFACTURING 9. AWARDS & ACCREDITATIONS

4. WINDOW FIT TING & TRANSPORT 10. RECENT PROJECTS

5. PANEL INSTALLATION 28. SUSTAINABILITY

6. PRODUCTS - RECON. STONE 29. MISSION STATEMENT

30. CONTACT TECHRETE

TA B L E O F C O N T E N T S

Founded in 1985, TECHRETE is the leading company in the design, manufacture and

installation of architectural pre-cast cladding, serving the UK and Irish construction markets. We offer a complete precast solution from bespoke design through to manufacture and erection.

Our success over more than 34 years is founded on the development of a manufacturing and technical expertise which dovetails state-of-the-art technology with skilled craft based processes.

By your side from design, to manufacture, to erection

We employ over 350 people in the UK and Ireland and boast a range of facilities at these locations. Our facility in Brigg, North Linconshire, together with our Balbriggan facility near Dublin, provides over 21,000m2 of production space and covers a combined site of 15 hectares.

Technical support is provided through our team of 50 engineers, estimators and draughtsmen, who are based in Enderby, Leicester and Balbriggan, Dublin.

A B O U T T E C H R E T E

1

+

DESIGN STAGE

To bring complicated shapes and geometry to life, many of our projects are modelled. This BIM compliant software used has been

customised to suit both our manufacturing process and our owninternal planning system (TIPS). Before beginning to model, 2D software is used to develop the initial design or sketch scheme. 3D modelling begins after the sketch scheme stage is approved. TECHRETE can choose from two 3D software packages and depending of the complexity of the job, it's deliverables and programme, TECHRETE will assess which package is best suited to the project.

ADVANCED STRUCTURAL ANALYSIS (FEA)For our more complex panel projects, a design process called Finite Element Analysis (FEA) may be used. Fusion 360 software simulates how complex panel shapes react to real working conditions and such conditions are the stages of handling a panel may need to go through before it is installed. Some panel types are removed from a mould base by tilting the panel up into a vertical position. Depending on the type of finish required and its extent, the panel may need to be rotated and/or laid down flat. Certain transport restrictions may be required to arrange certain panels in such a way that double handling on site is needed. When you have panels with this degree of handling during both its factory and transport life, a finite design element analysis is carried out to check the panels properties and lifting arrangements.

THERMAL IMAGING

Due to the ever changing requirements for more energy efficient buildings, the need for thermal design is paramount. Areas like thermal bridging, condensation risk analysis and fire-stopping solutions are calculated at TECHRETE to suit the U-Value requirements of the building. The latest thermal bridging software Psi-Therm version 6.0.2.a 2016 is used along with complying with the most up to date building regulations for both the UK and Ireland : BS EN ISO 13788, BS EN ISO 6946 & BS EN ISO 1077-2. TECHRETE will accurately determine the buildings insulation requirements using BuildDesk U version 3.4 in accordance with BS EN ISO 13788 & BS EN ISO 6946 and will recommend the best product from the range available to suit both the design and commercial constraints.

O U R H I G H LY S K I L L E D E N G I N E E R S P R O V I D E A C O M P R E H E N S I V E D E S I G N , D E V E L O P M E N T & D R A W I N G O F F I C E S E R V I C E U S I N G 2 D A N D 3 D S O F T W A R E P A C K A G E S

T E C H R E T E P L A N N I N G & D E S I G N

2

+

BALBRIGGAN, CO. DUBLIN

Our highly equipped manufacturing facility in Balbriggan was recently extended to encompass some 10,700m² of floor space, facilitating

up to 75,000m² of cladding per year. Special features include an internal finishing area, rain water harvesting and recycling system, computerized batching plant and bar bending equipment, acid etching building with effluent neutralisation, grit blasting facility, 25 tilting tables, automated polishing plant, 1 twin column mould, 9,500m² of yard storage served by a gantry crane and geothermal heating in the main office building.

CONTROLLED PRODUCTION

Panels are created in the exact shapes and dimensions specified by the designer and patterns. Reveals, joints and other expressive details can be added to the surface. Our precast concrete components are manufactured under controlled conditions, ensuring cost and material savings. Precast concrete allows for concurrent manufacturing activity which can speed up the entire construction process, eliminating costly delays and assist with tight time deadlines on-site.

BRIGG, NORTH LINCONSHIRE, UK

Our facility in Brigg was extended recently to 10,900m² and now houses the first carousel system for architectural cladding in the UK and facilitates up to 100,000m² of cladding per year. Special features include the carousel system with 28 stations, an internal finishing area, rain water harvesting and recycling system, computerized batching plant and bar bending equipment, acid etching building with effluent neutralisation, grit blasting facility, 7 steel tilting tables, 1 twin column mould, 1 adjustable steel curvebase and 12,000m² of yard storage served by 2 gantry cranes.

W E H AV E U N R I VA L L E D P R E C A S T M A N U F A C T U R I N G C A P A B I L I T Y I N T H E U K & I R E L A N D

T E C H R E T E M A N U F A C T U R I N G

3

+

PANEL TRAINSBespoke panel trains safely transport the panels in and out of the factory on tracks to the storage yards where they are racked and stored until ready for transport.This eliminates the requirement for trucks within the factories and also increases hook time for other activities on the factory floor.

TECH TRAILERS, 'A' FRAMES & FLATBEDSIn advance of site construction commencing, the site team submit a load sequence request to the TECHRETE transport department, who then confirm the sequencing based on safe access, geometry of the panels and type of trailer required. Our specialized trailers were designed to allow us to maximise panel sizes, facilitating the safe transportation of the largest of panels to site.

WINDOW FITTING

In addition to internal and external finishes, insulation and windows can be fitted. This is a highly cost-effective way to face a building, as the

only element which is finished on site in this case, is joining and sealing. We work alongside glazing contractors to facilitate installing their windows in the panels in safe, designated areas at all our premises.

T E C H R E T E W I N D O W F I T T I N G & T R A N S P O R TAT I O N

4

5 5 5

+

PRECISION & ACCURACY

Efficient erection of pre-cast concrete components demands proper planning and preparatory works. This includes the method and

sequence of assembly and erection, the provision of temporary supports, provision for final structural connections and joint details,calculation of erection tolerances and handling and rigging requirements. TECHRETE supervise site installation and maintain close liaison with the main contractor.

SPEED

Speed of panel installation has always been a key success factor in the use of architectural cladding. Over the years, TECHRETE has designed and developed items of equipment to facilitate complex manoeuvres, including a variety of C hooks, tilting rigs and counter balance rigs to facilitate the installation of panels under projecting framework. This is required in particular on high-rise buildings where installation of the pre-cast must start before the frame has been topped out.

SAFETYThe installation of TECHRETE precast panels and associated works is carried out by fully trained and competent operatives using certified equipment for each task at hand. Drafting and implementation of TECHRETE risk assessments and method statements is carried out with full communication with the main contractor which takes into consideration the ever changing aspects of a live site.

S E A M L E S S O N S I T E I N S TA L L AT I O N - A L W AY S S T R I V I N G F O R P R E C I S I O N , S P E E D & S A F E T Y

T E C H R E T E P A N E L I N S TA L L AT I O N

5

T E C H R E T EP R O D U C T S R E C O N S T O N E TECHRETE products are low-maintenance, fire-resistant,

durable, energy efficient, benefit from good acoustic performance and are of the highest quality. Inspection takes place at each stage of manufacture in accordance with the independently certified quality system - ISO 9001

Reconstructed Stone or recon for short, is by far our most popular product and it simulates the appearance and quality of natural stone.

There are many advantages to using this versatile material. Due to its inherent strength, 3D adaptability and the quality of textures, recon stone provides architects with an incredible amount of flexibility in terms of their design. Some further advantages include:

* Programme advantage with reduced site suration works* Panels can be cast in a variety of high quality shapes and sizes* Can be used as structural or non-load bearing cladding* More affordable than traditional construction materials * Low maintenance and low life cycle costs* No scaffolding or external hoisting needed* Reduces site impact - waste reduction* Achieves weather tightness faster than traditional build* Accoustic benefits* Reduces wet trades on site* Fire resistant * Pre-stressing is possible

6

B R I C K F A C E D N AT U R A L S T O N ET E C H R E T EP R O D U C T S A P P L I E D

Traditional building materials such as natural stone, as well as brick, terracotta and ceramic tile, can be applied to pre-cast

concrete in a process known as veneering.

The veneer material is incorporated during the casting phase and the resulting product benefits from all of the advantages of pre-casting, whilst maintaining the look and feel of traditional building materials and techniques. Our veneered products offer all of the same advantages over traditional buildings materials as TECHRETE reconstructed stone and GRC products.

Some further advantages unique to applied products are listed below: High accuracy moulds are created for the veneer, resulting in precision placing of the brick or tile finish

Applied materials weather well over time and there are a wide range of finish possibilities.

Complex features such as arches, cornicing, layered banding, cill and head detailing can be provided, avoiding the use of centres, site cutting and fitting.

Anti-gravity features can be pre-moulded, negating the need for cumbersone secondary support on-site.

T E R R A C O T TA / T I L E

7

H E AT H R O W E X P R E S SH E AT H R O W E X P R E S S K I N G S C R O S S T 1T E C H R E T EP R O D U C T S G R C

Glass Reinforced Concrete (GRC) is one of the most innovative construction materials available and provides

designers with complex aesthetics, as well as exceptionally high performance.

GRC panels which are generally ribbed or sandwich panels, provide durability, fire resistance, sound reduction and energy efficiency as well as the superior properties inherent in the material.

With one-fifth of the weight for the same solution in pre-cast concrete, this option is more suitable for areas with restricted access and gives the building structure considerably less loads.

GRC panels are lightweight but extremely strong and come in a wide variety of finishes and colours. Tough and impact-proof, they have unrivalled durability and are resistant to acid rain, ultra-violet light and freeze-thaw.

The glass fibres which are dispersed throughout the concrete, serve a similar purpose to the steel in reinforced concrete.

Pictured across, are three examples of GRC projects completed by TECHRETE.

L E W I S H A M G AT E W AY

8

Lombard Wharf, London

St. Peter's Square, Manchester

Exporter of the Year

L AT E S T A W A R D S & A C C R E D I TAT I O N S

V&A Museum, Dundee

Irish Export Business of the Year

V&A Museum, Dundee

9

18,000

8 , 7 8 7 M E T R E S V I C T O R I A & A L B E R T M U S E U M D U N D E E

C H A N N E L S C A S T

O F P R E C A S T P L A N K S

10

+

11

V I C T O R I A & A L B E R T M U S E U M D U N D E E , S C O T L A N D

Situated on the river Tay, the design of this striking

structure drew inspiration from the Scottish cliffs and the silhouette of the impressive facade imitates the shape of a ship at dock.

Design works began in June of 2015 with BIM 3D modelling (pictured) being utilised for the design of the precast planks and also to accurately pin point the exact locations for the fixings and 18,000 cast-in channels. Pioneering bespoke fixings were engineered by TECHRETE which contributed to the overall speed of the installation.

TECHRETE worked closely with the designer to agree a mix which would encompass all of the elements detailed in the brief.

The chosen finish consisted ofreconstituted granite with exposed aggregates.

Manufacturing commenced in August 2016 and was completed a year later. Two months of preparatory site works and a GPS system ensured the seamless installation of 8,787 meters of planks, which ranged in weight from 0.9 to 2.8 tonnes, all in a reduced time frame from the original 36 weeks, to 28 weeks.

Awards include 'British Precast Best Project 2018' and 'Tekla Award for Use of BIM 2018'

A W A R D

W I N N I N G P R O J E C T

12

299 6,413m2

134

F E E T TA L L

O F P R E C A S T C L A D D I N G

R E S I D E N C E S

R

L O M B A R D W H A R F, L O N D O N

TECHRETE C190

+

13

L O M B A R D W H A R F B AT T E R S E A , L O N D O N

Situated on Lombard Road in London, this multi-award

winning building comprises of 134 luxury and affordable residential units.

The building appears to twist as it rises, which was achieved with very subtle changes to the positioning of the white precast concrete balconies.

These subtle twists portray an appearance of carved stone. In order to achieve both this extraordinary shape and carved stone impression, TECHRETE were contracted to design, manufacture and deliver the architectural precast concrete cladding for the façade of Lombard Wharf.

The carved stone effect was an intricate and vital element of the build and the concrete mix selection was crucial. Selected was the creamy and light coloured mix with Mica, which added a sparkle.

The balconies were finished with a light acid etched finish. This exposed the natural aggregate and gives the balconies a more realistic stone feel. It was cast in a two-stage process ensuring a quality finish on all faces.

The resulting building went on to win awards in the Evening Standard New Home Awards, The Irish Concrete Society Awards and the What House Awards.

A W A R D

W I N N I N G P R O J E C T

14

6,789m2

573 O F P R E C A S T C O N C R E T E

P A N E L S E R E C T E D

V I C T O R I A G AT E , L E E D S

A W A R DW I N N I N G P R O J E C T +

15

V I C T O R I A G AT E L E E D S , E N G L A N D

Victoria Gate is located in the heart of Leeds City Centre

and was designed to incorporate a flagship John Lewis Store and internal shopping arcades.

The architectural precast concrete cladding on this inspirational project, demonstrates how far the limits of precast concrete engineering can be pushed.

Combining different acid etched and polished finishes within the various sections, a design with intricate geometry and a complex installation process, coupled with the utilisation of BIM 3D design tools, all demon-strates what can be achieved with precast facades.

The diagrid pattern was deconstructed by TECHRETE engineers to panelise a façade that would fit with precast manufacturing needs and yet not compromise the architectural intent.

Overall, the architectural pre-cast concrete cladding on the John Lewis store has created a unique and memorable identity and showcases just what can be achieved with such a versatile product and TECHRETE expertise.

Awards for this project include 'British Precast Creativity in Concrete 2017' and 'Irish Concrete Society International Project of the Year 2017'

16

5,9oom2

1,850

city of london

O F P R E - C A S T C L A D D I N G

P A N E L S

B U I L D I N G O F T H E Y E A R 2 0 1 6

1 N E W L U D G AT E , L O N D O N

A W A R D

W I N N I N G P R O J E C T +

17

1 N E W L U D G AT E L O N D O N

1 New Ludgate, is a retail and commercial development

located two blocks east of St. Paul’s Cathedral in London and was named the City of London Building of the Year 2016.

The system was designed to be installed without the necessity of external access.

The vertical fins were supported by a bespoke unitised curtain walling system and they were installed on-site with the glazing.

The horizontal ledges are supported on the concrete fins, acting as the horizontal restraint for the cladding as a whole and without interfacing with the glass cladding weather line.

The ground level columns and upper face of the spandrels are polished, which allows for better weathering and lower maintenance. The vertical fins and bottom face of the spandrels are grit blasted for a homogeneous street view.

The mix has been specifically designed using Spanish dolomite aggregates and pigments, to achieve this unique impact in the City of London.

Awards for this project include 'RICS London Award 2016, Best Commercial Building' and 'City of London Building of the Year.

18

7,210m2

120,000 sq ft

8 weeks O F O F F I C E S P A C E

T O E R E C T T H E C O N C R E T E P A N E L S

I N 5 4 6 U N I T S

2 S T P E T E R ' S S Q U A R E , M A N C H E S T E R

TECHRETE C190

+

19

2 S T P E T E R ' S S Q U A R E M A N C H E S T E R

2 St. Peters Square, is a truly distinguished building with

it's 12 floors rising majestically over the surrounding streetscape. The gable end faces onto Princess St and the building is adorned with delicate filigree tracery panels.

Drawing inspiration from the Lancaster Rose which adorns the county flag and from the Cotton Bud fountain, the tracery panels were designed to incorporate these elements whilst drawing on further inspiration from the town hall extension stair turrets.

The tracery panels are both decorative and functional and offer natural shading from the full height glazing which is situated behind them.

This choice of mix with a polished finish gives the building a timeless elegance appropriate to its prime location amongst such buildings of historical importance.

The panels on the main façades embraced the ethos of off-site construction. The windows were installed at TECHRETE production facility and were delivered and installed as one complete unit .

This resulted in a reduction in programme and in the amount of trades required on site.

This project won a 'Highly Commended' award at the

A W A R DW I N N I N G P R O J E C T

20

3,842m2 543 panels

O F B R I C K - F A C E D P R E C A S T C O N C R E T E C L A D D I N G

1 0 M O L E S W O R T H S T, D U B L I N

TECHRETE C190

+

21

1 0 M O L E S W O R T H S T D U B L I N

TECHRETE were engaged to design, manufacture and

erect over 3,500 m² of architectural brick faced precast concrete cladding panels, as part of the façade of number 10 Molesworth Street.

Chosen for our speed of erection and TECHRETE ability to provide for quality control of the brickwork and jointing, the architectural precast element consists of mullions, spandrels, parapets and stone-faced wall panels.

The carefully chosen mix was Techrete's timelessly elegant light, warm, off-white mix with an etched finish. To complement the mix, a natural stone-faced wall panel was chosen.

The brick wall panels offered a striking yet complimentary contrast to the reconstructed stone mix.

The chosen brick is a blended red colour range with off-white mortar joints. To keep with the Georgian tradition, the bricks were laid in a Flemish bond.

The building combines both traditional and contemporary design and with careful selection of materials and modern construction methods, the symmetry and overall appearance of the building has managed to adopt the genre of prestige that is synonymous with this area of Dublin.

22

5,574m2

484 panelsP R E C A S T C O N C R E T E C L A D D I N G

LOCAL BLACKFRIARS, MANCHESTER

TECHRETE C190

+

23

L O C A L B L A C K F R I A R S M A N C H E S T E R

Local Blackfriars is a beautiful gated residential

project, comprising 380 apartments, penthouses and townhouses across two striking towers, in Blackfriars, Greater Manchester.

The Blackfriar, a Grade II listed former public house, has been repurposed to act as a gateway entrance for the development.

This striking look of the towers was achieved using a combination of finishes. Throughout the buildings, the panels consist of a granite based reconstituted stone, with a polished finish and variations of green tiles cast into the panels.

An acid etched finish forms the base and crown or the top of the buildings, which provides the buildings with an elongated appearance.

TECHRETE were responsible for the architectural precast elements of the project and for the structural columns which sit from the base of the buildings to the second floor. These were also produced in a polished, reconstituted stone.

A key feature of this project from TECHRETE perspective, was the fixing of the balconies directly to the panels on-site, facilitating much simpler construction and installation.

KINGS CROSS T1

24

2,4009,000m2

O F G R C C L A D D I N G

P A N E L S E R E C T E D

TECHRETE C190

+

25

K I N G S C R O S S T 1 L O N D O NThe glass reinforced concrete mix was a marvellous deep terracotta colour and this was acid etched and detailed with patterns which as a result, reveal a diverse pattern in the finished façade of the building.

In order to obtain the richly ornamented façade, the concrete used in the casting of the panels was a light weight glass reinforced concrete (GRC).The mix chosen to give the Tapestry building its' unique colour, was a reconstructed stone with a range of natural aggregates, sands and pigments .

Awards include 'Best Mixed Use Development 2017' and 'RIBA London Award 2017'

Kings Cross T1, also known as the Tapestry building,

focussed on creating a unique and distinct building which stands amongst many newly developed buildings.TECHRETE were contracted to design, manufacture and erect the façade. TECHRETE had been a part of several other developments within Kings Cross and for this T1 project, wemanufactured 2,400 panels which contributed to creating a sustainable building. The Tapestry buildings'sustainability goals were achieved through the landscaping, design and the choosing of architectural pre-cast cladding.

A W A R DW I N N I N G P R O J E C T

C O N S I S T E N T LY R E D U C I N G O U R C A R B O N F O O T P R I N T I S AT T H E H E A R T O F O U R B U S I N E S S

+S U S TA I N A B I L I T Y AT T E C H R E T ECare for the environment is at the heart of everything we

do at TECHRETE and our committment to reducing our carbon footprint is evidenced by the significant investments we have made during the past five years in energy efficient and environmentally sustainable processes, equipment, workshops, office facilities and management systems.

Our approach in this area consists of two main strands. The first is our ultimate goal of a zero-carbon footprint for our production processes and the second approach consists of analysis of our end product.

The inherent properties of pre-cast concrete make it a natural choice for achieving sustainability in modern construction. Our products have a high thermal mass which facilitate the absorption, storage and radiation of heat which is fundamental to sustainable construction for the future.

Techrete has been presented with the prestigious Green Award on many occasions including the 'Green Manufacturer of the Year Award', for striving to help prevent climate change by reducing waste, carbon emissions and water consumption.

*Figure represents the change in results over the last 5 years in our production plant in Ireland.

**Figures represent the change in results over the last 5 years for both facilities in the UK and Ireland.

***Figure represents UK gas supply

26

**co2 emmissions IN KG Per M2

**recycled tonne of waste per m2

***carbon off-set on gas supply

solar energy generated since 2016

*Harvested rain water used in production 51%

176%

817,000 kWh

100%

43%

27

“WE HAVE BUILT A FAMILY OWNED BUSINESS WHICH IS BASED ON THE PRINCIPLES OF INTEGRITY, HONESTY, LOYALTY, SAFETY & QUALITY. OUR COMMITTMENT TO BOTH OUR CUSTOMERS & OUR EMPLOYEES IS PARAMOUNT IN EVERYTHING WE DO.

OUR OBJECTIVE OF ACHIEVING THE PROJECT TARGETS IN THE SAFEST WAY POSSIBLE & ENSURING A RESULT OF UNSURPASSED QUALITY DRIVES

EVERYTHING WE DO. THE LOYALTY DISPLAYED BY OUR CUSTOMERS BY AWARDING US WITH REPEAT BUSINESS OVER THE YEARS, IS THE CORNERSTONE OF OUR FORWARD ORDER BOOK.

EVERYBODY INVOLVED IN OUR PROJECTS FROM OUR CUSTOMER, TO THE TECHRETE PEOPLE WHO EXECUTE THE WORK, ARE ALL TREATED AS PART OF THE TECHRETE FAMILY.

THE ETHOS OUTLINED ABOVE, IS THE LIFE BLOOD OF OUR BUSINESS.

MARCUS SWEENEY, TECHRETE CHAIRMAN

"We have built a family owned business which is based on the principles of integrity, honesty, loyalty, safety & quality. Our committment to both our customers and our employees is paramount in everything we do. Our objective of achieving the project targets in the safest way possible & ensuring a result of unsurpassed quality, drives everything we do. d The loyalty displayed by our customers by awarding us with repeat business over the years, is the cornerstone of our forward order book. Everybody involved in our projects from our customer to the TECHRETE people who execute work, are all treated as part of the TECHRETE family. The ethos outlined above, is the l ife blood of our business." Marcus Sweeney, TECHRETE Chairman

CONTACT US LEICESTER : +44 1162 865 965

BRIGG : +44 1652 659 454

LONDON : +44 20 3771 5655

DUBLIN : +353 1 6901700

EMAIL : ESTIMATING@TECHRETE.IE

WWW.TECHRETE.COM

CONTACT US

LEICESTER : +44 1162 865 965

BRIGG : +44 1652 659 454

LONDON : +44 20 3771 5655

DUBLIN : +353 1 690 1700

EMAIL : ESTIMATING@TECHRETE.IE

WWW.TECHRETE.COM