Natural Stone and Modern Methods of Construction

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Natural Stone and Modern Methods of Construction

• Contemporary Architectural Solutions

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Ian RobottomAndrew Shutt

• Stancliffe Stone

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Aim

• Provide an understanding of how Stone can be used
  in traditional modern architecture
• Indicate the various fixing options.
• Consider the advantages each option offers
• Look at design / build considerations

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Outline

• Brief history of the Stone Industry
• Introduction to Stancliffe Stone
• Current advances within the Stone Industry
• Traditional Handset Masonry
• Stone on Precast concrete
• Full Wall Rainscreen System

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Stancliffe Stone Today

• Acquired by Marshalls plc in 2001
• 5 - 6M of re-investment
• 2001 6 quarries / 2 manufacturing plants
• 2008 15 quarries (14 stones) / 5 manufacturing
  plants

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Sustainability

• Sustainable Development is about achieving
  economic growth, environmental protection and
  social progress at the same time

Sustainability
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Integrated Management Registration (IMR)

• Basis to build sustainable operations by
  utilising PAS 99 (management system requirements
  specification) to combine the following 3
  management systems.
• ISO 9001 2000 Quality Management Systems
  Requirements
• Provides a number of requirements which an
  organization needs to fulfil if it is to achieve
  customer satisfaction through consistent products
  and services which exceed customer expectations.
• ISO 14001 2004 Environmental Management
  Systems Specification with Guidance for Use
• The ISO 14000 environmental management standards
  exist to help organizations minimize how their
  operations negatively affect the environment,
  comply with applicable laws, regulations, and
  other environmentally oriented requirements, and
  continually improve on the above.
• OHSAS 18001 1999 Occupational Health and
  Safety Management Systems Specification.
• A management system to document and control the
  operations of an organisation to ensure that
  health and safety of all stakeholders is
  maximised by a clear system of risk analysis
  continual review of operations and procedures. to
  ensure Health and Safety controls remain relevant
  to developing operations.

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Integrated Management Registration (IMR)

• Aim to have Integrated Management Registration
  (IMR) at each of the fifty six sites as a basis
  upon which to build sustainable operations.
• Registered and Audited by BSI and Marshalls
  internal auditing team 4 times per year.
• Current roll out plan is ongoing for Stancliffe
  2 sites currently have full IMS.

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Sustainability
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Range of Stones

• Buff / Buff Grey Sandstones
• Stanton Moor
• Stoke Hall
• Fletcher Bank
• Howley Park
• Scoutmoor
• Darney
• High Nick
• Talkin Fell
• Doddington
• Halldale
• Red Sandstones
• Locharbriggs Red Sandstone
• Red St. Bees (2 quarries)
• Plumpton Red Lazonby (2 quarries)
• Limestones
• Cavendish White
• Creeton Hard White
• Creeton Silverbed

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Stone Cladding and Modern Fixing Options

• Traditional Handset
• Stone on Precast Concrete
• Natural Stone Rainscreen cladding
• Full Wall Integrated Rainscreen Cladding

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1. Traditional Handset
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Traditional Handset Masonry

• Split into two Sections
• Section 1
• Rubbed Face Walling
• Pitch Face Walling
• Split Face Walling

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Rubbed face walling
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Rubbed face walling
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Split face walling
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Traditional Handset Masonry

• Rubbed Face, Pitch Face Split Face Walling
• 100mm on bed
• 10mm Joints
• Standard Cavities and Wall Ties
• Course Heights up to Blockwork size (215 mm)
• Covered by BS 5628 32001

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Traditional Handset Masonry

• Section 2
• Ashlar Cladding

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Ashlar Cladding
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Ashlar cladding
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Ashlar Cladding
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Ashlar cladding
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Traditional Handset Masonry

• Ashlar Cladding
• 75 / 100mm thickness
• 5mm Joints
• Dowelled Fixings
• Course Heights to Specification
• Covered by BS 8298 1994

Facing thickness
Cavity
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Traditional Handset Masonry

• Design / Construction Considerations
• Full Loadbearing external leaf, usually cavity
  wall Construction, support restraint fixing
  solution.
• Solid Appearance (L shaped quoins etc, available
  if required).
• Traditional Build generally requiring scaffolding
  (Possibly Masonry Scaffolding).
• Masonry Design Fix Companies are probably
  required.

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Traditional Handset Masonry

• Time Consideration For
• Masonry Design
• Procurement
• Production
• Fixing Period

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2. Stone on Pre-cast Concrete Units
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Stone on pre-cast units

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Stone on pre-cast units
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Stone on pre-cast units
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Stone on Pre-cast Concrete Units
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• Stone 40mm or 50mm thick.
• Angled dowels fixed into back of stone.
• Stone laid into carcass moulds.
• Concrete poured onto back of stone.
• Generally 6mm joints.
• Covered by BS 8298 1994

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Working Drawings
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Stone on Pre-cast Concrete Units
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Stone on Pre-cast Concrete Units
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Stone on Precast Units
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Stone on Pre-cast Concrete Units

• Design / Construction Considerations
• Stone 40mm or 50mm thick.
• Panellized System may show up on large areas of
  stonework.
• May Require some areas of handset stonework.
• Long lead-in period.
• Fast Track Site Programme.
• Units Hung on Frame.

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Stone on Precast Concrete Units

• Time Considerations for
• Detailed Design of Stones for each panel.
• Stone Procurement.
• Stone Production.
• Stone / Precast Unit Manufacture.
• Panel Curing Period.

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3. Natural Stone Rainscreen Cladding

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Rainscreen cladding
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Rainscreen Cladding
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Rainscreen Cladding
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Natural Stone Rainscreen Cladding

• Definition
• Rainscreen Cladding is a layered cladding system
  typically comprising an outer skin which
  incorporates air gaps but forms the primary rain
  barrier, a ventilated air gap that prevents water
  ingress, and an effectively impermeable backing
  wall.
• CIMclad 2001

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Natural Stone Rainscreen Cladding

• Principles
• To allow the ingress of air at the base of the
  system and the egress of air at the top of the
  system.
• This ventilated cavity allows any water which
  penetrates the panel joints to be partly removed
  by the stack effect and also by running down
  the rear face of the panels and out of the base

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Natural Stone Rainscreen Cladding
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Natural Stone Rainscreen Cladding

• Design / Construction Considerations
• Panel / Curtain wall appearance.
• Lightweight structure
• Speed of Insulation
• No Wet Trades
• Off Site Preparation
• Covered by BS82981994 Thickness of stone
  unless proved by structural calculation or
  performance testing

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Natural Stone Rainscreen Cladding

• Time Considerations for
• System Design
• Procurement
• Production
• Fixing Period

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4. Full Wall Integrated Rainscreen Cladding
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Full Wall Integrated Rainscreen Cladding

• Natural Stone Curtain Walling
• Lightweight Inner Wall
• Fully Insulated
• Fully Waterproof
• Single carrier system for internal wall
  external stone rainscreen cladding.

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Step 1 - Primary structure edge beams
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Step 2 - Attatch extruded aluminium mullions to
structure.
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Step 3 - Insulation and fire rated wall panels
are clamped between gaskets into the mullions.
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Step 4 - Extruded aluminium stone carrier rails
are attached to the front of the mullions.
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Step 5 Stone Rainscreen panels are fitted to
the carrier system
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Cherry Picker or MEWPs installation
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Installation
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Full Wall Integrated Rainscreen Cladding
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• Design / Construction Considerations
• Lightweight Construction
• Reduced wall thickness
• High Thermal resistance
• Airtight Construction
• Complete integral wall system
• Install with MEWPS (Mobile Elevated Work
  Platforms - scaffolding not necessary)
• Rapid Installation
• Covered by BS82981994 Thickness of stone
  unless proved by structural calculation or
  performance testing

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Full Wall Integrated Rainscreen Cladding

• Time Considerations
• System Design
• Procurement
• Production
• Fixing Period
• Building is weatherproof, so external leaf is off
  the critical path.

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There are many deciding factors that affect the
choice of stone / system

• Appearance
• Building Design and Construction
• Site Constraints
• Cost Comparisons and Models

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Conclusion

• Review of Stone Industry
• Four Fixing Options
• Traditional - Handset Masonry
• Stone on Pre-cast Concrete Units
• Rainscreen Cladding
• Full Wall Integrated Rainscreen Cladding
• Design / Construction Considerations
• Time Considerations

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Questions?