MMC Techniques

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Combining traditional with innovative

It is important to establish right from the start that, where MMC is used, the final product may
still be a mix of traditional and innovative technologies. A number of house builders, for
example, continue to build houses in a traditional manner, but use sub-assembly technologies
as well. Preplumbed and fully fitted-out en-suite wc and shower room pods complete with
plastic tiles and grout are now available and can be incorporated into traditional masonry
construction. Even some of the panel systems which are delivered to site complete with a
facade of brick slips are likely to require the skills of a bricklayer to join the panels up at the
corners. There are so many ways to build, and so many variations on a theme, it is best not to
have too many preconceived ideas about the building you may be about to survey, until you've
finished your inspection. Cost is still a driving force in the contruction industry. At present, the
prospect of losing our manufacturing base to our overseas competitors seems unlikely, given
the potentially huge transportation costs.
Construction techniques fall into the following broad categories:
panel systems;
volumetric systems;
sub-assemblies and components; and
on-site technologies.
In some forms of construction a mixture of technologies is employed, such as bringing together

volumetric and panelised systems. These are categorised as hybrid systems.
Panel systems
As the name implies, where these systems are used, the manufacturer produces a large
factory-made panel from either wood or metal. The panel is then either delivered as it is, or
enhanced depending on the client's wishes. Enhancement could be adding insulation,
services, internal or external facings, windows and doors, or all of these. Completed panels
are then delivered to site and fitted together. The way in which the DPC works, or the
interaction between internal walls and the roof may differ from project to project. Often the
contractor or developer will be choosing the materials and forms of construction for other parts
of the building. By using highly energy efficient foam insulants, the thickness of timber can be
reduced as low as 89mm.
Galvanised light steel C-section metal can also be used for metal-framed buildings. The
insulation is added to the outer side to prevent cold bridging. The frames are used for the
walls, floors and roof trusses and are used in combination with a wide variety of other
products, including traditional brick outer skins, cladding, insulated render and screed floors.
There are also mobile rigs that allow the frame to be made on site.
Concrete panels have been around for many years (in high-rise blocks of flats for example)
and concrete panels with brick slip facings are also being manufactured. Another variation is
'structurally insulated panels' or SIPs. The panels consist of an outer facing of timber-based
boards bonded to rigid insulation. They fit together with male/female joints and are clamped
together on site. They are very strong and can be used in roof and wall construction.
Page 1.
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Figure 1: Hospital extension with self-supporting Metek structure walls and flooring
This photograph is reproduced with permission from Metek Building Systems - part of the
MMP Group
Volumetric systems
Unlike panel systems, volumetric systems consist of a room or whole floors being factory
made, and craned into position on site - often with one unit sitting on top of another. The use of
materials can be similar to some forms of panel construction, in that the carcass is often made
from lightweight steel, which is fitted together and then insulated and lined internally. The
services are prefitted, and connected on site to risers or other service provisions.
Volumetric forms have been popular in student accommodation projects, hotels and some fast
food outlets. Sometimes referred to as pods, they can be integrated into traditional forms of
construction. The external facade can also be constructed on site to suit planning conditions.
Some manufacturers even fit out the internal space, complete with carpet, wall coverings and
fixed beds and desks.
One feature of volumetric systems is the thickness of floors and walls. Each unit has its own,
so consequently the floor depth and wall thickness are likely to be greater than those in
traditional construction. The walls are also likely to be load bearing.
Page 2.
Figure 1: Module with brickslip for Innovation Park at BRE
This photograph is reproduced with permission from Metek Building Systems - part of the
MMP Group
Sub-assemblies and components

Some contractors use a mixture of technologies. Preplumbed hot water systems have been
available for some time, as have electrical looms and associated services.
Floor and roof construction has also progressed. Prefabricated floor beams emerged a few
years ago - they give longer spans, are less prone to squeak and come complete with
knockouts for services. Whole floor and roof assemblies are now available. The floor is made
to fit in the factory, from traditional flooring-grade chipboard, supported by a lattice of steel
webs, large enough to receive waste pipes or light steel beams. Craned into position, they
offer enormous savings on time and offer the benefit of being able to pass services through.
Plasterboard ceilings however, are still site-fixed. The same principle applies to roof
construction, where the contractor can order prefabricated roof assemblies which are rigid and
insulated, to be installed, for example, in cross wall construction or from eaves to ridge.
BubbleDeck
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BubbleDeck is a form of construction, which as the name implies, incorporates bubbles into
the construction in order to reduce the dead weight. The concept has been popular in
Denmark and Holland for over 10 years. The bubbles are created from incorporating recycled
hollow plastic balls in between the steel reinforcement, before the concrete is poured.
Under manufactured conditions, the plastic bubbles are trapped between the top and bottom
reinforcement, and cast into a concrete biscuit to create a semi-precast unit. The unit is then
craned into position and concrete is poured on top, the lower section acting as permanent
formwork.
The site concrete is poured on top to form a structural topping. The load transfers in two
directions back to the columns or load bearing walls. The use of a splice rebar joint stitches the
panels together to enable spans over 21 metres to be designed. In a more traditional form of
precast concrete flooring, the floor 'planks' span from beam to beam in one direction, which in
turn dictates the length of the span. These beams of steel or concrete can be seen to the
underside of the floor and are known as 'downstand' beams. Bubble Deck construction
eliminates the need for downstand beams.
How can you spot them? You can't, so look through the health and safety file and look for the
absence of downstand beams.
Page 4.
Figures 1-2: BubbleDeck
Figures 1-2 are reproduced with permission from BubbleDeck. For more information go to
BubbleDeck
Flooring
Page 5.
Figure 3: Timber PosiJoist floor cassette under construction off site
Page 6.
Figure 4: Finished PosiJoist floor cassette ready for shipment
Figure 5: PosiJoist floor cassette being lowered into position - note the deep service
void beneath the floor finish
Page 7.
Figure 6: Floor construction nearing completion
Figures 3-6 are reproduced with permission from AC Roof Trusses Ltd
Bathroom options
Figure 7: Accessible WC
Page 8.
Figure 8: Rear view of preplumbed services
Page 9.
Figure 9: Section of completed product
Figures 7-9 are reproduced with permission from Concargo Composites
Page 10.
On-site technologies
The application of thin bed mortar techniques is still very popular, albeit the skills required to
apply the mortar are different from traditional brick laying skills. Another form of construction is
insulated concrete formwork. There are many manufacturers but the principle remains the
same. Hollow polystyrene blocks are fitted together with male/female connectors, and built up
in stages before reinforcement is added and concrete pumped and tamped into the void. There
are no lintels over openings, and the insulation remains in place to dry line or to render
externally. It is quick, lightweight and simple to use.
Figure 1: Insulation and brick tie system
Figure 1 is reproduced with permission from Metek Building Systems - part of the MMP
Group.
Page 11.
Figure 2: External walls being assembled
Page 12.
Figure 3: External walls - note internal spacer bars and position of reinforcement
Page 13.
Figure 4: The concrete is levelled off in a traditional manner
Page 14.
Figure 5: Door opening former in position
Page 15.
Figure 6: Note how the insulating block is easily positioned over the opening
Page 16.
Figure 7: Traditional timber joists form floors
Page 17.
Figure 8: Precast concrete floors being installed
Figure 9: External stone cladding held with flexible wall ties
Figures 2-9 are reproduced with permission from the Insulating Concrete Formwork
Association
Brick slips
Brick slips are also popular and in general are applied in one of 3 ways:
bonded to a concrete panel and then pointed;

mechanically clipped and then pointed; or
glued onto an insulated backing panel and then pointed.
The insulation can be premoulded to incorporate neat setting out lines and L-shaped slips are
available for returns. Note that warranty providers may not allow bricks slips or other cladding
forms to be directly bonded onto the frame itself, and will wish to see a drained cavity
incorporated into the design. They may also require third party certification of the system. In
the absence of a cavity, there are therefore no DPC or trays or weep holes.
Historically, much attention has been given to thermal movement and frost action which can
Page 18.
'pop' the slips, but today's manufacturing processes rely on flexible adhesives that give the
bond an element of elasticity. The mortar can be applied in the factory or on site in a process
similar to cake icing, with a premixed workable mortar.
Figures 10-11: Brick slips
Page 19.
Figures 10-11 are reproduced with permission from Hanson Building Products
Page 20.

MMC Techniques

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http://www.isurv.

Combining traditional with innovative

Construction techniques fall into the following broad categories:

In some forms of construction a mixture of technologies is employed, such as bringing together

Figure 1: Module with brickslip for Innovation Park at BRE

Sub-assemblies and components

Figures 1-2: BubbleDeck

Figure 3: Timber PosiJoist floor cassette under construction off site

Figure 4: Finished PosiJoist floor cassette ready for shipment

Figure 6: Floor construction nearing completion

Figure 8: Rear view of preplumbed services

Figure 9: Section of completed product

Figures 7-9 are reproduced with permission from Concargo Composites

Figure 1: Insulation and brick tie system

Figure 2: External walls being assembled

Figure 4: The concrete is levelled off in a traditional manner

Figure 5: Door opening former in position

Figure 7: Traditional timber joists form floors

Figure 8: Precast concrete floors being installed

Figure 9: External stone cladding held with flexible wall ties

bonded to a concrete panel and then pointed;

Figures 10-11: Brick slips

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