INCA Case Study: Ropeworks, Barking

The Genesis of Ropeworks Transformation

The Ropeworks in the heart of central London stands as a beacon of residential life, with its 8-story structure housing 246 flats, a police station, a children’s nursery, and a library. Constructed between 2006 and 2008, this building soon became a cornerstone of the community, surrounded by schools, businesses, and iconic landmarks.

However, the evolution of building safety standards necessitated an upgrade. The introduction of The Building (Amendment) Regulations 2018 and the eligibility for fire remediation through the Building Safety Fund catalysed a comprehensive makeover for The Ropeworks, spearheaded by Guildmore, a leading industry contractor.

A Quest for Safety and Comfort

The primary objective of this extensive project was to replace the existing cladding systems with fire-safe alternatives and improve the building’s overall thermal efficiency. Intrusive surveys uncovered combustible materials within the walls, prompting an ambitious re-cladding effort to achieve an EWS1 rating. This complex undertaking, spanning approximately 132 weeks, included several meticulous phases:

1. Preparatory Works: Scaffold erection in three phases and temporary waterproofing.
2. Cladding Works: Removal and replacement of various cladding and insulation materials, ensuring adherence to fire safety standards.
3. Balcony Works: Removal and installation of new balcony materials, enhancing safety and aesthetics.

Overcoming Challenges

Executing this project within a live residential environment posed unique challenges. The presence of a nursery and church required careful coordination to ensure the safety of children and minimal disruption to religious activities. Active commercial units and the proximity to a town hall demanded meticulous planning to maintain accessibility and respect municipal functions.

The need to protect a prominent statue necessitated the installation of protective barriers and continuous surveillance. Additionally, erecting scaffolding above the library required structural engineering expertise to ensure the integrity of the building below.

Technical Prowess and Collaboration

The involvement of specialised suppliers for rainscreen and EWI systems was crucial. These collaborations ensured the design, supply, and compliance certification of materials, with a focus on sustainability through local manufacturing and waste recycling.

The integration of Soltherm’s EWI systems brought about a transformative impact. The Ultimate HD Silicone EWI System, tailored to the specific needs of the project, significantly improved thermal efficiency and fire safety. Extensive intrusive surveys guided the accurate ordering of materials, addressing varying insulation thicknesses and substrate differentials.

In the realm of fire remediation projects, the Soltherm range of External Wall Insulation (EWI) systems emerges as a transformative force. This transformative potential extends beyond the technical nuances into the holistic realm, where a confluence of factors produces significant advantages. Soltherm specified two key specifications, the Ultimate HD Silicone (EWI) and Solus HD Silicone (render only), each tailored to this specific project’s requirements. The EWI was primarily applied to the courtyard areas, attributing for approx. 2000m² and a third of the total façade area.

Addressing the challenge posed by the substrate – a concrete-framed construction with lightweight steel infill – Soltherm engaged in extensive intrusive surveys during the project’s early stages. This meticulous approach ensured accurate material orders, particularly regarding insulation thicknesses, a critical consideration given the substantial lead times associated with mineral wool procurement at the project’s inception. The intrusive surveys proved their worth, revealing varying insulation thicknesses of 180mm, 170mm, 120mm, 110mm, and 80mm, while also identifying differential substrates. The systems were finished in a white 1.5mm silicone render finish. Along with colour accent features to match that of the original building design, which were various shades of white and green. The courtyard presented an array of detailing challenges, encompassing balcony interfacing, concealed rain pipes, parapets, rendered soffit extensions, and lightning conductors.

Beyond these technical details, Soltherm’s EWI systems offer holistic benefits that resonate throughout the project and beyond: Fire Safety Enhancement: Soltherm’s EWI solutions incorporate A1 rated fire safety materials, elevating the fire safety rating of residences to meet the highest standards. This pivotal upgrade instils a sense of security and peace of mind, safeguarding lives and property. Energy Efficiency Revolution: External wall insulation isn’t just a surface-level improvement. It immediately impacts the operational costs of residential buildings by curbing heat loss and alleviating the burden on heating technology. This translates into tangible energy savings, contributing to sustainability goals and cost-effectiveness, weatherability and resilience:

In an era characterised by the escalating threat of climate change, Soltherm takes centre stage with its robust, durable systems. These systems exhibit impressive impact resistance, standing resolute against the rigors of the elements year-round. By enhancing weatherability, Soltherm’s solutions prolong the lifespan of structures, ensuring they remain resilient and visually appealing over time. In essence, Soltherm’s EWI systems extend well beyond their technical specifications, ushering in a new era of fire safety, energy efficiency, and structural longevity. As shown at the Ropeworks project, these systems are rewriting the narrative of remediation projects, infusing them with a comprehensive and transformative approach that touches every facet of the built environment. In the wake of such advancements, buildings not only regain their original appearances but also gain newfound strength, safety, and efficiency, reflecting Soltherm’s commitment to a safer and more sustainable future.

Integration of Other Façade Systems

• PPC Aluminium Rainscreen: Chosen for its sleek and durable finish, polyester powder-coated aluminium ensures longevity and weather resistance. It enhances energy performance by reducing energy loss, creating a more comfortable interior environment.
• External Wall Insulation (EWI): EWI integration significantly improves thermal efficiency, reducing energy loss, and enhancing interior comfort.
• Curtain Walling Interface: Achieving seamless junctions between new façade systems and existing curtain walling while preserving the integrity and aesthetic of the original curtain walling was a critical challenge.
• Integration of Existing Doors and Windows: The pre-existing doors and windows required careful consideration during the introduction of new façade systems. Ensuring harmonious and functional integration while maintaining the original character and functionality of these elements was vital to the project’s success.

Thermal Performance Enhancement

120mm = 0.28W/m²K, 80mm = 0.39W/m²K, 170mm = 0.22W/m²K, 180mm = 0.20W/m²K

Energy Performance Improvement:

• Before U-Value of the Rainscreen Wall Type: 0.28 W/m²K
• Achieved U-Value of the Rainscreen Wall Type: 0.22 W/m²K
• Before U-Value of the External Wall Insulation Wall Type: 0.28 W/m²K
• Achieved U-Value of the External Wall Insulation Wall Type: 0.18 W/m²K

The comprehensive fire safety and energy performance improvements undertaken at The Ropeworks stand as a testament to Soltherm’s innovation and Guildmore’s dedication to creating a safer and more comfortable environment for the residents of this central London residential development.

Contributory Factors Making it a ‘Stand-Out’ Project

The remediation efforts undertaken within this project encompassed a remarkable transformation, addressing 264 balconies (with some flats boasting multiple balconies) and spanning a wide range of critical improvements. This holistic approach was meticulously designed to not only enhance the structural elements of the building but also instil a profound sense of safety, security, and community well-being.

• Balcony Repairs and Replacements: The project’s scope extended to the repair and replacement of 264 balconies, accommodating the unique needs of flats with multiple balcony configurations. This revitalisation not only contributed to the aesthetic appeal but also ensured the safety and functionality of these vital living spaces.
• Enhanced Building Performance: The remediation strategy encompassed a multifaceted approach, integrating crucial components such as:
• Replacement of Decking: The rejuvenation of decking materials ensured both durability and visual appeal, contributing to the overall quality of life for residents.
• External Wall Insulation (EWI) Systems: Soltherm’s cutting-edge Ultimate system took centre stage, showcasing its industry-leading attributes. These systems featured A1-rated non-combustible mineral wool, elevating fire safety standards to levels between A1 and A2-s1,d0. The compliance of these systems for high-rise projects throughout the UK was pivotal in providing residents with the utmost peace of mind here at Ropeworks.
• Rain Screen Cladding: The inclusion of rain screen cladding not only improved the building’s exterior aesthetics but also bolstered its weather resistance and longevity.

Innovative Silicone Systems

Soltherm’s commitment to innovation was evident through the incorporation of encapsulated biocides within their Ultimate silicone systems. These biocides not only thwarted the growth of algae and mould but also extended their effectiveness, surpassing standard biocides. This technical enhancement not only contributed to the visual appeal of the building but also preserved its structural integrity.

Community Well-Being and Safety Assurance

Beyond the technical aspects, the project generated profound benefits for the residents and the broader community. Residents now rest easy knowing that the building no longer poses a fire safety risk, thanks to the completion of the Building Safety Fund (BSF) works. This newfound sense of safety resonated deeply, considering the building’s strategic location and proximity to significant establishments, including a nursery.

The ripple effect of this assurance has created a closely-knit and at-ease community, where residents share in the collective comfort of a safer and more secure living environment. This sense of well-being transcends the physical aspects of the remediation project, ultimately nurturing a harmonious and thriving community that cherishes its home.

Client Testimonials

The residents and stakeholders of Ropeworks have expressed immense satisfaction with the project’s outcome, highlighting the enhanced safety, improved energy efficiency, and the overall positive impact on their daily lives.

For a detailed visual journey through this transformation, visit our video case study. https://www.soltherm.co.uk/case-studies/ropeworks-fire-remediation-project/

The Ropeworks project stands as a beacon of innovation and dedication, showcasing the transformative power of holistic remediation efforts in enhancing safety, efficiency, and community well-being.