Module 6: Case Studies & Practical Applications
6.1 Real-World Projects
1. Post-Grenfell Fire Safety Retrofits
Case Study: UK ACM Cladding Replacement
Issue: Hundreds of high-rises (e.g., Chalcots Estate, London) found with combustible ACM (PE core) post-Grenfell.
Solution:
Full System Replacement: Non-combustible materials (A2-rated mineral core ACM, ceramic-coated steel).
Enhanced Fire Breaks: Cavity barriers at every floor (complying with BS 9991).
Compartmentation: Intumescent seals around windows/doors.
Outcome: Reduced fire spread risk; cost £3–5M per building (funded by UK’s Building Safety Fund).
2. High-Performance Facades
Commercial: The Edge, Amsterdam (BREEAM Outstanding)
Features:
Solar-Active Glass: Adjusts tint to optimize daylight/heat.
Integrated PV Panels: Cladding generates energy.
Rainscreen System: Recycled aluminum panels with 0.18 U-value.
Takeaway: Cladding can drive net-zero energy goals.
Residential: Park Hill, Sheffield (Heritage & Modernization)
Challenge: Retrofit 1960s concrete brutalist flats.
Solution:
Insulated Metal Panels: Improved thermal performance without altering historic facade.
Ventilated Cavity: Prevented condensation in concrete structure.
Result: Cut heating costs by 40% while preserving aesthetics.
6.2 Hands-On Workshop (Optional)
1. Mock Installation Exercises
Activity 1: Rainscreen Panel Fixing
Task: Install aluminum panels on a mock subframe using concealed clips.
Focus:
Alignment Tolerance: Max ±2mm deviation.
Waterproofing: Apply sealant to joints (mock rain test with spray bottle).
Activity 2: Fire Barrier Installation
Task: Fit mineral wool fire breaks around a simulated window opening.
Key Lesson: Gaps >3mm fail compliance (BS 9991).
2. Defect Identification & Remediation
Common Defects:
Thermal Bridging: Infrared camera demo to spot cold bridges.
Poor Sealant Application: Hairline cracks causing leaks (remedy: remove/reapply Dow Corning 795).
Incorrect Fixings: Rusted screws in aluminum panels (replace with stainless steel).
Exercise:
Inspect a pre-built "defect wall" with 10+ errors (e.g., missing weep holes, unsealed joints).
Teams compete to document/fix flaws fastest.
Key Takeaways
Workshop Outcomes
Certification: Participants who pass defect identification receive a "Cladding Inspector" micro-credential.
Real-World Prep: Live demo of drones for facade inspections (identifying cracks/delamination).
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