INCA Case Study: Bull Bridge Mead, Modular Homes

Cutting-edge Solutions in Modular Façade Systems for Net Zero Ready Homes

Bull Bridge Mead is a development of eight modular homes in Halstock, Dorset built specifically for shared ownership and rent. The landowners, a local couple who wanted to give young people a chance to get on the property ladder and stay in the village, approached Magna Housing to deliver an affordable homes scheme. 

This project is a collaboration between Wetherby Building Systems, Rollalong, Magna Housing, and TLS Construction SW, supported by the South West Procurement Alliance. The partners are dedicated to accelerating the delivery of modular homes in the UK using offsite manufactured, precision-engineered techniques to modernise and expedite the construction process.

Wetherby’s Modular System was specified for this project along with two finish variations. The timber frame properties were expertly constructed in Rollalong’s modular factory, with the Wetherby Modular Brick Slip system also installed in the factory prior to transportation to the Halstock site.

The timber frame substrate was sheathed in 12mm cement particle board, with the Modular EPS System directly affixed to the board. The project utilised the Wetherby Modular EPS System in two finish variations, incorporating Enhanced Grey EPS in sizes of 165mm and 190mm, selected for its efficiency and cost-effectiveness. The system’s closed-cell structure prevents water absorption and endures various climatic conditions, making it ideal for the exposed rural location.

Four of the properties were finished with Wetherby Brick Slips as part of the Modular system, utilising the Tivoli colourway—an attractive red brick with orange tones. This highly impact-resistant system can be installed swiftly, with a complete application achievable in just one day.

Wetherby’s technically approved and certified Modular EWI systems can deliver energy-efficient solutions for any units constructed offsite, with decorative finishes applied either in a factory before site delivery or after modules are positioned onsite. The teams chose to install the Stone Slip system onsite, executed by Wetherby-recognised installer TLS Construction SW.

The Wetherby Stone Slips finish was employed for the inaugural time on this project following its launch. The Stone Slips finish in the colourway ‘Buff’ adorned two of the properties to uphold the traditional aesthetic of the area, complemented by a natural mortar. This pioneering approach blends the authentic appearance of natural stone with the advantages of modern construction techniques.

The stone system is mounted on a stainless steel mesh, ensuring robustness and longevity, while providing a guide for the slips. This economical and cost-effective reconstructed stone wall cladding maintains an authentic natural stone look. It provides a professional, real stone finish and offers a faster application compared to traditional methods, eliminating the manual handling challenges associated with conventional stone and brick materials.

The project utilised a four-module solution, allowing for efficient construction in challenging rural locations with space limitations. The steps and staggers configuration enhances fire safety and acoustic performance, reflecting the project’s commitment to high standards and safety.

The Bull Bridge Mead project faced logistical challenges, including negotiating low bridges, narrow country lanes, and power lines. Despite these obstacles, the project was completed within a 12-week construction program, showcasing the efficiency and adaptability of the modular construction approach.

This project is part of the government’s initiative to achieve net zero carbon homes by 2050, built to Part L compliance, offering superior insulated facades and efficient heating, making them cheaper to run than traditional homes.

In this modular building project, meticulous attention to energy efficiency has yielded exceptional results, achieving an impressive U-value of just 0.18 W/(m²K). This achievement not only enhances the comfort and efficiency of the building but also exemplifies our dedication to delivering cutting-edge solutions in construction.

This project highlights the team’s commitment to modernising the housing delivery process through offsite manufacturing and precision-engineered techniques.

Client Feedback:

Magna Housing

“I am sure we can all agree that the stonework looks amazing, and the finished homes certainly do not look like a factory-built product!”