Category: MMC
How much does rationalisation influence the early design thought process?
Why is drainage an issue when it comes to designing a project?
Why are Prefab Balconies the New Choice for High-Rise Developments?
Traditionally, balcony construction has often been an afterthought in the building design, and concrete balconies don’t make the process any easier.
With the more efficient and sustainable modern methods of construction, off-site manufacturing and prefabricated balconies are transforming projects.
Here are 7 reasons why prefabricated balconies are the new choice for high-rise residential buildings:
- Increased Perceived Value: Prefab balconies are manufactured off-site, focusing on functionality, sustainability, and aesthetics. Improved visual appeal contributes to a building’s market value as high-quality finishes, sustainable materials, and functional designs appeal to buyers. Additionally, because prefab balconies are produced efficiently, developers benefit from cost savings through reduced waste and faster installation.
- Enhanced Thermal Efficiency: Step codes are driving the push for increased thermal performance in new Canadian constructions. Heat can easily escape through balcony structures without proper thermal breaks, undermining the building’s energy efficiency. Prefab balconies allow manufacturers to place thermal breaks in tactical locations within the balcony system to reduce heat loss in the building, leading to improved thermal performance.
- Higher Project Efficiency: Prefinishing balconies off site reduces the need for on-site trades as there is no manufacturing of balconies in situ. Delivering fully assembled units also means faster balcony installation.
- Unmatched Quality Assurance: Balconies that are produced in controlled factory conditions undergo several quality checks, ensuring that each balcony has a trackable history. For example, at Sapphire we use the Passport App to record and track each balcony’s progress through the different production and quality check stages.
- Ideal for Passive House Developments: Thermally broken balconies increase energy efficiency and reduce heat loss, aligning with passive house principles. Prefabricated aluminium balconies also lower structural load as they are lightweight and complement sustainable building frames like cross-laminated timber frames.
Learn in our case study how we streamlined the balcony project at Vienna House, a passive house residential development in Vancouver, Canada.
- Higher Design Flexibility: Off-site manufacturing allows for more opportunities to create a functional balcony design that offers comfort to residents and simplifies installation and on-site handling of balconies by installers. Prefinished balconies can be thoughtfully assembled in the factory while keeping the risk of error as low as possible.
- Compliance with Standards: Features like thermal breaks in prefab balconies improve energy efficiency by lowering heat transfer, supporting compliance with standards like the Toronto Green Standard. Sustainable balcony design can also contribute to lower TEDI ratings.
Discover in our case studies how our prefabricated balconies have benefited projects across the UK and Canada.
What Is Anchor Homing and Why Does It Matter?
How Can Off-Site Production Transform Your Balcony Project?
Sapphire has embraced and applied modern methods of construction to all its projects, from using standardised designs to off-site production and storage. We aim to minimise on-site work by finishing our balconies in our factories, leading to various benefits for our clients.
What are the Key Benefits of Off-Site Balcony Production?
- Increased Quality Assurance: Producing balcony units in a factory setting ensures higher quality control. Our balconies go through strict quality checks and using our Passport app we ensure that a balcony passes on to the next production stage after it’s passed the previous one, ensuring a higher quality output and less repetition of work.
- Increased Perceived Value: Off-site balcony production increases the quality of output. Therefore, every balcony installed will be high quality, increasing the condo’s value.
- Fewer Project Delays: Health and safety issues related to hot work during the installation of traditional balconies are minimised, and so is the risk of errors.
- Faster Balcony Installation: We have been able to rapidly install over 60 Glide-On Cassette balconies in a day. As the balconies are prefinished in our manufacturing plant, installation becomes faster and requires fewer on-site trades.
- No Storage Requirement: Pre-finishing as much as possible in the factory minimises the need for secure storage on-site, which is especially beneficial for projects in city centres where space is limited.
Discover how our prefabricated balconies benefited a passive-house residential development Vienna House in Vancouver, Canada.
How Does Off-Site Production Contribute to a Project’s Sustainability Goals?
- Less Waste Generation: When balconies are manufactured and finished off-site, there is a lower chance of product defects and material waste.
- Innovative and Sustainable Design Possibilities: Off-site manufacturing gives innovators the chance to design and produce prefabricated balconies that are energy-efficient and sustainable. For example, our balconies are all thermally broken, leading to improved thermal efficiency in the building.
- Shorter Construction Period On Site: Off-site production leads to project efficiency by reducing balcony installation time and on-site trades, saving construction time and carbon emissions.
Discover how our off-site production techniques and prefabricated balconies have reduced carbon emissions, time, and costs in our case studies.
At Sapphire, we believe that well-designed balconies benefit property developers and buyers significantly. Our balconies are constructed with functionality, sustainability, and aesthetics in mind. Through off-site production, our team can execute innovative designs with accuracy, enhancing our balconies’ perceived value.
If you have a project in mind and wish to discuss it, start a conversation about prefabricated balconies in Canada with us: www.balconies.global/contact-us/
What is StubGuard®?
[vc_row width=”70″ background_image=””][vc_column][sapphire_textBlock]In the wake of Grenfell and the introduction of the combustible cladding ban of 2018, fire safety and thermal performance in modern construction have become the highest, non-negotiable priorities when developing housing, especially in high-rise buildings where balcony connections present unique challenges.
What is StubGuard®?
Presented with the challenge of protecting the horizontal fire barrier while effectively penetrating it to allow for a balcony connection, Sapphire has created an innovative solution: the StubGuard®.
StubGuard® seamlessly integrates into horizontal cavity barriers, fixed via wrap compression for a secure fit on balcony anchors and is suitable for cavities up to 300mm wide.
Fire barrier and thermal performance benefits of StubGuard®
StubGuard® is an essential component of the cavity barrier system when connecting a balcony, and helps developers meet strict fire safety regulations, including Gateway 2.
Certified under Certifire® and tested to BS EN 1366-4, StubGuard® provides a compliant and reliable fire-stopping solution while simplifying the installation process.
StubGuard® is designed to protect the continuity of the fire barrier by acting as a consistent fire protection element. This eliminates the need for down stands, maintains a seamless protective layer, and has effective fire-stopping integrity and insulation for up to 120 minutes.
When used with Sapphire’s new G25 steel stub, the need for a wraparound of the I-beam is reduced, making it easier to integrate into the facade due to a smaller profile streamlined abutments. Thanks to our dedicated research and development team, we’ve been able to optimise the chi (χ) value per connection, reducing thermal bridging and enhancing overall building performance.
StubGuard® is often included with Sapphire balcony anchors and can be requested for most projects, allowing projects to benefit from this advanced fire-stopping technology. Now available with a smaller profile on our G25 anchor steel stubs, simplified abutments, and proven fire performance, it is a game-changer for achieving compliance without complexity.
For further details, we can provide full test reports upon request. To explore the science behind fire safety in balcony design, read the full StubGuard® data sheet now.[/sapphire_textBlock][/vc_column][/vc_row][vc_row width=”70″ background_image=””][vc_column][sapphire_contentLinkBottom image=”3619″ heading=”Technical Manual – StubGuard®” button_text=”Read now” button_link=”url:http%3A%2F%2Flocalhost%2Fbalconies%2Ftechnicalmustread|title:Technical%20Manual%20-%20StubGuard%C2%AE|target:_blank”]Sapphire’s must read documents on StubGuard®.[/sapphire_contentLinkBottom][/vc_column][/vc_row][vc_row width=”70″ background_image=”” el_id=”” el_class=”” css=””][vc_column][vc_raw_html css=””]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[/vc_raw_html][/vc_column][/vc_row]
New Road Triangle, Feltham
Chequers Lane, Dagenham
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“I’ve been working with Sapphire for around 10 years. Good as gold and wish every company would take a leaf out of your book. 10/10.
– Project Manager, Hollybrook Limited
History
Developed in tandem with Transport House, Kerwin House (formerly the Chequers Lane development) was a redevelopment of the Ford Stamping Plant in Dagenham, East London. The London Borough of Barking & Dagenham worked alongside developer Hollybrook to deliver approximately 3,000 residential units across all phases, as well as a 10FE Secondary School, the plan was also developed with the London Plan in mind, seeking ‘zero carbon homes’ across the whole development.
Streamlined by Innovation, Delivered by Sapphire
With the London Plan for sustainable development in mind, developer Hollybrook aspired to create a series of new, environmentally friendly, MMC-built residential developments in Dagenham fit for both now and the future. Hollybrook & Sapphire had collaborated in tandem on other developments in the area such as Transport House, so building upon the previous relationship was a crucial starting point.
A constraint of this development was the requirement for a balcony on the first-floor level over ‘hunched’ stubs, whilst a separate elevation required a balcony on the ground floor over deep roof insulation.
Sapphire streamlined this development by innovation, using our StubGuard® over the ‘hunched’ stubs to protect the continuity of the fire barrier and benefit the thermal performance across each balcony.
We also created a ‘free-standing’ balcony on the ground floor level to sit over deep roof insulation. The balcony was designed to sit on four galvanised steel support posts, designed by Sapphire. The balcony was lifted and fitted to these posts and, once the steel beams within the balcony cassette were bolted to the posts, the final lining and levelling of the balcony was completed.[/sapphire_textBlock][sapphire_contentLink order=”Image left / content right” image=”13193″ heading=”Discover Sapphire’s Next Generation Balcony” button_text=”Discover” button_link=”url:http%3A%2F%2Flocalhost%2Fbalconies%2Four-product%2Fthe-next-generation-balcony%2F|title:The%20Next%20Generation%20Balcony”]The Next Generation Balcony is a huge step forward for the construction market[/sapphire_contentLink]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
Transport House, Dagenham
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“I’ve been working with Sapphire for around 10 years. Good as gold and wish every company would take a leaf out of your book. 10/10.
Project Manager, Hollybrook Limited
History
Situated on the former site of the Unite trade union in Dagenham, Transport House brings 149 new residential units to the area, with the building itself touted as a sustainable development, using air-source heat pumps to reduce the building’s carbon footprint whilst the building is in use, reducing the CO2 emissions by 20% compared to a gas boiler and 70% when compared to an electric system.
Streamlined by Innovation, Delivered by Sapphire
Be First and Hollybrook aspired to deliver environmentally friendly, MMC-built homes fit for both now and the future in Dagenham. Both they, and Sapphire, had collaborated once before on the Chequers Lane development, so building upon the previous relationship was a crucial starting point.
With over half of the development designated as affordable housing and 100% of the development focused heavily on sustainability, Transport House needed to utilise old brownfield sites successfully to create more affordable housing. With Transport House, the key principles followed throughout were good quality housing, green spaces, pedestrian links and sustainability, designed to celebrate Dagenham’s industrial heritage whilst providing residential space for the growing community.
Hollybrook and Be First, however, were constrained by needing to hit sustainability goals. By using a precast sandwich façade panel, embodied carbon and water was reduced, making the development resource-efficient from a very early stage. However, adding balconies to a precast façade became a sticking point, as special connections would be needed in order not to compromise the sustainable benefits of the precast façade.
Once Sapphire came on board, we worked closely together with Hollybrook and Be First to ensure the project could be streamlined by innovation. We used a cast-in bracket on the façade panels, providing tie-wire connections that could clip onto the cast-in anchors. These tie-wire connections were not only more sustainable due to their small penetrations but also did not penetrate the fire barrier at all, making them safer to use. By triangulating the forces with a clip-on tie-wire connection, moment forces can be reduced on top of reducing embodied carbon and water penetration, making the balcony far more efficient to construct in the first place and taking weight off of the building structure, making Transport House energy efficient and sustainable both on completion and well into the future of its tenancies.