Balcony Rigidity Wows at Blackfriars

Balconies at Local Blackfriars in Salford, Manchester are among the most rigid achieved to date, eclipsing the British standard for deflection of L/180.

Heritage and modern architecture blend beautifully at Local Blackfriars as the Grade II-listed former pub has been transformed into a gateway entrance to the gated community. In a nod to the local history, the former Black Friar pub is flanked by two striking modern towers that provide 380 apartments to the area.

Concrete wall panels were chosen for this project which the contractor wanted to connect balcony bracket to, in lieu of the slab. To meet this challenge we designed a bespoke bracket that maintained the thermal break inside the cavity, while also meeting our Rigid.Ready.Right. brand promise.

The specialised brackets were produced and cast-in at the concrete wall panel manufacturer’s factory in Dublin before being shipped back to Manchester for install.

Our brand promise guarantees all our balconies will be Rigid.Ready.Right. first time. This means they must meet a minimum of L/360 deflection which is twice as rigid as the British standard. At Local Blackfriars we achieved an outstanding 0-1mm deflection when tested with a 200Kg weight making these some of the most rigid balconies installed to date.

Not only did we manage an extremely high rigidity result, we worked harmoniously with other trades to ensure the smoothness of the project programme. All 290 Glide-on™ Cassette® balconies were prefinished offsite at our production facility in Staffordshire ahead of the agreed delivery date and securely stored ready to be called to site.

The balconies were then ‘nested’ onto each pallet to optimise transportation costs and efficiency, reducing the number of lorries arriving to site and reducing emissions.

The concrete wall panels required the use of the crane Monday-Friday, so we scheduled delivery and install of our Glide-On™ balconies on weekends. This way crane costs could be minimised, the project could progress quickly, and synergy could be reached between the different trades active on the project.

The simplicity of the Glide-On™ innovation enabled teams to achieve 30 per day meaning lost program time caused by other trades could be caught up.

The result, exceptionally rigid balconies wowed at Local Blackfriars and provided residents with essential private outdoor space for a bustling central Manchester lifestyle.

Residents benefit from communal facilities including a reception, laundrette, cinema room, fitness studio, bike storage and car parking space. This development offers luxury living with their extensive indoor facilities as well as access to a relaxing ‘urban orchard’ between the towers.

Situated just two-minutes’ walk from Manchester’s vibrant shopping district, the lively northern quarter and the buzzing nightlife of Deansgate and Spinningfields. The development was designed by 5Plus Architects and delivered by Salboy.

This article was originally featured in Insight Magazine, subscribe for your free copy every quarter here.

Balcony install achieves a rapid 34 in just 6 hours 13 Minutes.

New approach, new balcony install record.

With exceeding balcony install expectations in mind, Sapphire working with a Scottish balcony install partner, set a challenge to install more than Sapphire’s long-standing record of 22 balconies in one day. Having hit this goal with 23 installed at Pomona Wharf earlier in June, a further 34 balconies were installed in just 6 hours and 13 minutes of balcony installation time on 15th June 2017. That’s an amazing install average of just 10.9 minutes per balcony all day long. Testament to Sapphire’s unique and patented Glide-On™ Cassette® balcony systems, which enables install of fully assembled balconies in rapid times and with improved safety from the traditional bolt-on balcony approach.

Sapphire’s patented Cassette® balcony system is complementing the innovative design and build of a new high-rise development on Pomona Island, one of Greater Manchester’s ‘hidden gems’. The offsite-manufactured system’s fast-track install method, using Sapphire’s patent-protected Glide-On™ connectors, made it possible to install 23 balconies one day and a further 34 projecting balconies during another day, with just three installers and one crane (in two set up positions). Rowlinson Construction’s Project Manager comments:

“Although we hadn’t worked with Sapphire’s modular balcony system before the balcony install  went very well and we are all happy with the end product”.

The two adjacent buildings at the new Pomona Wharf development are part of the regeneration of the former dockland site. The 10 and 11 storey apartment blocks have been constructed as complete precast concrete solutions. Individual sections of each building’s shell and envelope were delivered to site ready to be craned into position floor by floor.

Offsite production fundamental

Working in tandem with the build programme, Sapphire manufactured over 100 balconies for the project in its offsite lean production facility. Once each building’s floor slabs were cast, complete with thermally broken balcony brackets and cantilever arms. Sapphire began scheduled deliveries of fully assembled balcony units to site. The individual balconies, including glass balustrades and sub-deck, were installed by simply lifting them into position and ‘gliding’ them on to the arms – this method of balcony install saves time and minimises crane hire and associated site costs. A simple solution, unique and patented by Sapphire.

Balconies for the project feature frameless structural glass balustrades from Sapphire’s Crystal range, combined with an slim aluminium capping and durable, slip-resistant WPC composite decking. Unsurprisingly, glass balustrades are a popular choice for residential balcony projects like Pomona Wharf. As well as its enduring aesthetic appeal, glass offers a robust, low maintenance solution. In addition, Sapphire’s unique and simplistic base detailing design enables integration with the Cassette® structure avoiding the need of base channels which are often one of the most costly parts of a frameless structural glass balustrade, making Cassette® balconies a cost-effective choice for developers.

Increasing offsite

Offsite construction methods, as used at Pomona Wharf, are increasingly seen as the answer to many of the issues facing the construction industry; from increasing margins for contractors to addressing the housing crisis by reducing build times and labour requirements. Sapphire’s Marketing Manager, Nick Haughton, says Sapphire very much supports this approach. He comments:

“To install 57 balconies in just two days, especially with only a three man balcony install team and a single crane is simply beyond the conceivable possibilities of traditional bolt-on balconies. The achievement of installing 34 balconies in a single day sets a new industry record and is clear testament to our patented balcony innovation”.

Rapid balcony install is not about rushing and mustn’t compromise safety. It’s primarily down to innovative design of balconies, and about working lean and ensuring intelligent sequencing to minimise delays. Sapphire’s supply and support approach meant balconies were ready and right, enabling installers to complete balconies rapidly with installers safely inside the apartments, and without need to install soffits afterwards.

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