Creation of a Hybrid Insulated Structural System to Enable Delivery of a Disruptive High Volume House Building Model – Hyb-ISS

Traditional site-based construction methods are a major negative contributory factor to the UK's housebuilding industry's famously low productivity and the sector is increasingly struggling to attract the skills it needs.

Offsite construction in the housebuilding industry promises hugely improved productivity, performance and consistently high standards, supported by full implementation of digital technology. Yet, less than 10% of construction currently occurs offsite.

Growing demand, coupled with less-than-optimal build quality and a reducing skills base, has created a dilemma that will not be resolved without a 'step change' in productivity and quality of build. Offsite construction benefits include consistency, quality assurance (including a 'Golden Thread' of traceability from specification to installation, as recommended by the Hackitt Review), faster construction times, reduced waste, minimised defects and less hazardous working conditions.

In its 2017 White Paper, the Government outlined a range of initiatives, and a target for the industry to build at least 250,0000 new affordable houses year on year to 2039.

Fusion Building Systems (trading name of Salvesen Insulated Frames Limited), Aggregate Industries (part of the LafargeHolcim group) and Crest Nicholson will collaborate in the Hyb-ISS project to develop materials, and a factory-based process, for production of finished, non-combustible, pre-insulated structural panels for house walls, roofs and floors. A range of products will be fully compliant with the latest digital technologies under Building Information Management (BIM) protocols. For the first time in a reduced-weight panel, advantages of offsite manufacture, zero combustibility and improved and fully traceable build quality will be available to the industry. A 10% -- 15% build cost reduction, and build lead-times shortened by ~30% compared to onsite construction will be targeted in support of the government's goal to build 250,000 houses year on year to 2039.

The project will provide prototype materials and process, and prototype pre-insulated panels for preliminary fire, thermal, acoustic and structural testing and evaluation (initially in exterior and separating wall applications) in field trials with major housebuilder, Crest.