At
The Ropeworks, 1 Arboretum Place, Barking, Essex, 1G11 7GT
Outline Method Statement for Cladding Removal
November 2020
Guildmore Ltd, 61 Widmore Road, Bromley, BR1 3AA
19046-GM-RW-XX-RP-B-9000-P02
Document Issue Register
Date Revision Comments 10/10/20 P01 For Comment 20/10/20 P02 Revised following comment
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OUTLINE METHOD STATEMENT FOR CLADDING REMOVAL
1.0 Introduction
The following document details our proposals in relation to the works to be carried out at The Ropeworks, 1 Arboretum Place, Barking, Essex, IG11 7GT. This document will continue to be developed prior to commencement on site and will be amended as necessary and to the benefit of the Client and Project Team.
1.1 PROJECT SCOPE OF WORKS
The Contract is a Design & Build Scheme encompassing, in the main, the stripping of Trespa cladding and remedial work or replacement to several cladding systems
The works include (but not limited to):
• Site establishment & temporary works • Erection of fully designed scaffolding • Intrusive Investigation of substrate to inform remedial works
• Temporary enabling works.
• Removal and disposal of Trespa rainscreen cladding to main façade and Balcony Areas • Remedial work substructures, backing wall, support structures, insulation, membranes cavity
barriers and other components as required
• Installation of new fully compliant rain screen cladding to main façades and Balcony Areas
The following will detail our proposed programme of works, site facilities, accommodation, material storage and distribution and waste management for the block. We will also further develop our traffic and pedestrian management and fire plans for these areas in line with our methodology as set out within this Construction Method Statement.
1.2 SITE GEOGRAPHICAL POSITIONING
The Ropeworks is located in Barking Town Centre. Access is available to the building directly off Axe Street which lies to the North of St Pauls Road and West of the A123 (Ripple Road). The Ropeworks is a residential development in Barking Town Centre. Originally built around 2006-2008, the development comprises of a U-shaped apartment block with eight storeys which sits above a 2 storey library for part of the buildings footprint.
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Ground Floor Plan from AHMM drawing 18056 (12) _101 001
Typical Residential Floor Plan from AHMM drawing 18056 (12) _102 001
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Aerial view
THE
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2.0 Construction Methodology
2.1 COMMUNICATION.
All operatives will attend the project induction
2.2 CONSTRUCTION LOGISTICS & METHODOLOGY
Stage 0 Investigative works
We have identified the areas for selective removal of cladding and insulation to assess the condition and workmanship within the façade as shown on our marked-up drawings. These areas have been selected to allow examples of all the main interface details to be investigated, while exposing a large representative area of the façade.
It is proposed that the opening up intrusive inspections will be executed from a MEWP, which can be operated from town square and other areas beside the building. Heras fencing will be erected around the MEWP to protect the public during the works.
Pull-out / load testing will be carried out to the new brackets, subject to dimensional checks.
Cladding panels and insulation will be carefully removed and stacked in a location away from the building. Where the breather membrane is also cut away or where it proves unfeasible to temporarily reinstate removed panels, a weathering membrane fire resistant to LPS 1215 standard will be installed.
Only hand powered or selected electrical tools (drills, cut-off saws etc.) will be used, as they pose a lower risk as ignition sources. There will be no portable generators used.
Stage 1 Site set up and preparatory enabling.
We agree that the best potential compound location is in the existing service yard as this requires no licensing from the council. Our site accommodation, welfare facilities and materials storage will be located in this area.
The principal compound will be protected by a full hoarding with appropriate signage and security, with lockable vehicular gates for deliveries and a fingerprint operated turnstile for pedestrians.
We also propose to engage the council to seek a license for a much smaller, delivery-only compound along the edge of the civic square, positioned to give access to our goods hoist while maintaining public access through the covered concourse. The hoarding to the secondary delivery compound in the civic square could be offered as a canvas for local artists to enhance its appearance during the works.
Guildmore will be responsible for maintaining these facilities in safe condition and good decorative order throughout the works and for making good to any damage to the landscaping prior to demobilization.
Stage 2 Scaffold erection and enabling works.
Having reviewed all of the options, we have concluded that it will be necessary to erect a scaffold to all façade areas, up to and including the parapet of level 7.This will allow the formation of a ‘total-wrap’ solution which will protect the works area and open parts of the facade from the elements. Temporary works designs will in particular be required where scaffolding spans the carpark entrance, and to reflect the structural layout and bearing capacity of the roof of the existing building. Scaffold will be erected sequentially around the building to correspond with the proposed phasing as outlined below.
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Stage 3 Removal of cladding and insulation
The building has been divided into 12 sections, each terminating at an existing vertical firebreak. Stripping of balcony cladding, façade cladding, cladding rails, insulation and defective fire breaks in each section will proceed from top to bottom to minimise potential risk from spread of fire.
Potentially flammable materials will be removed from the building as they are stripped and not stored on scaffolding. The stripping of each floor within each section will be carried out just ahead of the reinstatement works so that large areas of façade are not left exposed to the elements for long periods.
Where any delay is anticipated between removal and reinstatement, the exposed area will be covered with fire resistant sheeting to LPS 1215 standard. Guildmore will ensure that appropriate general fire precautions are implemented to maintain means of escape, fire-fighting and means to sound an alarm are provided for construction workers, and decide if these need to interconnect with systems provided within the building.
A suitable Fire Action Plan will be prepared to specify what to do in the event that a fire breaks out within the building and how that might affect the construction workers and evacuation from the building.
Stage 4 Reinstatement works.
The general sequence of work will start in the NW corner and aim to complete the elevations facing the public square (sections 1-5) first. This allows the scaffolding (and potential second delivery compound) to be demobilized at the earliest opportunity, so minimizing inconvenience to the local community. The works will then continue around the NE, SE and remaining SW elevations as shown on the gridline diagram below.
Replacement breather membrane, cladding brackets, insulation, fire stopping and finally external cladding panels will be installed and fixed in accordance with the design for the wall insulation and cladding system as defined by the designers, manufacturers guidance, and as approved by the Building Control Authority. The relevant information from the design drawings, Employer’s Requirements and manufacturers guidance will be collated into our QCS document to give clear and unambiguous instructions to the operatives actually executing the installation.
The accuracy and completeness of their work will be monitored via Guildmore’s QCS system, including a geographically identifiable photographic record of each section of the works. The reinstatement of balcony cladding panels will be the last task before the scaffold is struck.
Stage 5 Handover.
Client and audit inspections will be scheduled throughout the works to provide all parties with comfort that the installation is in accordance with the required standards. A phased handover is proposed, whereby the elevations facing the public square are completed, inspected and handed over first, allowing the scaffold to be struck. Remedial works which may be required to the spayed columns or soffit (as identified by the investigative works), can be carried out from a MEWP after the scaffold strike, enclosed with a temporary Heras fence.
Upon completion of all elevations, we will decant all welfare / office accommodation and make good to any hard and soft landscaping affected by our works.
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Proposed Programme of Works
Works are scheduled to commence on site in March 2021 with completion in September 2021, subject to Pre-Construction: Investigative & Design Work.
• Pre-construction: Investigative & Design work: Dec. 2020 – March.2021 • Construction: Façade Remedial Works on site: March. 2021 – Sept. 2021
Continuous liaison with the tenants / occupiers of the building throughout the works to ensure minimal disruption in close co-ordination with the Employers Agent.
Only hand powered or electrical tools (drills, cut-off saws etc.) will be used, as they pose a lower risk as ignition sources. There will be no portable generators used.
2.3 TEMPORARY WORKS
A full temporary works design will be implemented encompassing the scaffolding (where used).
2.4 FURTHER ARRANGEMENT INFORMATION
• Guildmore will adopt the existing The Ropeworks Fire evacuation procedures • All deliveries and collections will be controlled, and deliveries arranged so as not to disrupt occupants.
• All pedestrian routes will be physically segregated from vehicular areas. • Herras type fencing will be erected around operational MEWP’s • All hoardings will be illuminated and have vision panels installed. • Pedestrian access will be maintained for The Ropeworks Library staff, residents and visitors. • Directional signage will be erected at various appropriate locations around the site both internally (to
transmit key information to our construction teams) and externally to keep The Ropeworks Library staff, residents and visitors informed of the safe segregated routes.
• ‘Project Directory’ boards will be erected, at agreed locations, to promote the project and the associated team members and these will detail such things as (but not limited to), site contacts / emergency numbers.
• No parking will be permitted around the site during the construction works phase. All operatives will be encouraged to use public transport facilities as the site is very well serviced in that regard.
2.5 FACILITIES & ACCOMMODATION
Guildmore have been allocated an area within the site for welfare and office accommodation for the duration of the project. AHMM drawing 18056 (12) _101 001.
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3.0 Material Storage & Distribution
3.1 MATERIAL STORAGE
To service the project we will require temporary storage for materials taken down and to be disposed of and a storage area for construction materials etc. which will be located within the site area (to be confirmed) . Additional storage will be sourced off site via a local depot with materials being transported via smaller shuttle style vehicles where appropriate.
3.2 MATERIAL DISTRIBUTION
Materials will be distributed from the storage areas on a daily basis to the workface.
4.0 Waste Management
4.1 TASK MANAGEMENT
The Site Manager will be responsible for ensuring the smooth flow of waste from the site.
A waste management area will be located on site and will be segregated from The Ropeworks Library staff, residents and visitors with Herras Type fencing. The area will be carefully monitored on a daily basis to ensure that it is kept clean and clear.
We will ensure our site facilities do not disrupt local waste pick-ups and/or block any emergency access routes.
4.2 DAY TO DAY WASTE MANAGEMENT
The site will operate a day-to-day waste management system with all waste being removed from the workface and relocated to the skips within the site compound daily.
4.3 RECYCLING MANAGEMENT
The site will operate a recycling policy whereby segregated bins / skips will be placed within the site service yard.
5.4 Recycling Reports
The site will record and monitor all waste transferred from the site. This is achieved by using our approved recycling contractor who provides us with a monthly report on all materials / waste taken to the transfer system together with the full breakdown of the materials & weights transferred.
As a further means of reducing environmental impact we will receive all transfer notes electronically thus reducing the paper used for this operation.
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5.0 Traffic Management
5.1 SPECIFIC TRAFFIC ARRANGEMENTS
The controlled movement of traffic and pedestrians involved in the project is imperative to the correct running of the site.
The health and safety of all operatives, vehicles and pedestrians accessing the site or through the construction zone / protected access point shall be maintained at all times.
The control of traffic movements around the site and lifting and storage of materials must be maintained to provide a safe working environment.
The control of security at the site will be implemented to ensure the passage of vehicles onto the site is monitored, therefore avoiding a build-up of traffic on the adjacent highway.
The control of vehicle debris (i.e. dust, mud and oil) will be controlled to provide minimum impact on surrounding property and highways.
A project traffic management plan will address the following:
• Site entrance and exit; • Vehicular movements; • Pedestrian movements (occupied residential building); • Parking; • Site storage; • Material Deliveries; • Maintenance of adjoining Highways; • Dust control; • Site accommodation / welfare; • Site lighting; • Noise Management; • Environmental protection.
6.0 Pedestrian Management
The Ropeworks will be occupied throughout the works and access ways to/from the building will be identified, protected and maintained. Existing fire escape routes to and from The Ropeworks will be maintained and available.
Pedestrian barriers will be erected around the work area to keep unauthorised people away from work activities. These will be removed at the end of each shift and area left clear.
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7.0 Security Statement
The access to and from, and the security of The Ropeworks will always be a high priority. Regular liaison will take place to ensure co-operation and co-ordination between occupants and users of the building and the Contractors.
All scaffolding and MEWPS etc. will be locked down and inaccessible out with normal working hours.
8.0 Project Signage & Signboards
We shall install warning signage around the work area including:
• Site safety • Men working overhead • Safe Pedestrian Routes • Traffic Management Plan
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SITE SET UP AND METHODOLOGY
1.0 Access and site set up including ensuring safety of residents and surrounding users. This is one of the most public sites in Barking, at the heart of the civic centre and surrounded by public amenities including the Town Hall, Barking Learning Centre, Medical Centre, Leisure Centre, Theatre and Police Station.
The main challenge is to maintain safe and unimpeded access to all of these facilities while reconstructing the exterior of a very large mixed-use building. It is also important to ensure that the appearance and presentation of the works do not detract from this important civic space.
Our site setup proposals have been designed to minimise disruption to residents, neighbours, users of the adjacent civic, commercial and religious buildings, and members of the public and our aim is to identify the solution which minimises daily inconvenience to the public while facilitating the most rapid method of delivery for the works – noting that the cumulative inconvenience of low-impact but long-running works can ultimately outweigh a slightly higher level of inconvenience experienced over a much shorter time.
We note and concur with the proposed location for the site compound in the delivery yard just off Axe Street. This is the logical place for our site accommodation and delivery compound, whereby vehicles will be able to offload directly to the base of our goods hoist, minimising double-handling of materials.
A local depot will be used for longer term storage so that materials can be called to site using smaller flat-bed truck type vehicles. Traffic in all cases will approach the site via the roundabout at St Pauls Road, turning into Broadway and turning again into either Axe Street or Clockhouse Avenue. In both cases, the constrained layout is such that vehicles will need to be reversed into and driven out of the delivery compound under full traffic marshall supervision. These local roads are in all cases relatively lightly trafficked so this manoeuvre does not present an unacceptable risk.
All waste will be removed daily from the workface to segregated material skips within the site compound. All waste leaving site will be logged via our Smartwaste system and our recycling contractor will provide a monthly report outlining the type and weight of materials removed and the recovery / recycling rate. As part of our CSR activities, we will try to identify local groups who may be able to reuse these materials. For example, recycled cladding panels are much in demand amongst allotment holders for the creation of raised beds and planters.
We also offer an alternative approach for consideration, whereby a second compact delivery yard would be set up on the paved square, adjacent to the raised steps. This approach would allow a second hoist to be brought into service and unlocks the possibility of multiple teams working across two workfaces in parallel without being constrained by the logistics of material distribution, resulting in a shorter project programme. It also minimises the manual handling of large quantities of material at high level around this very large building, with attendant benefits to health and safety.
Being a highly prominent location, the hoarding in this area would need to be of especially high quality, possible offered as a canvas for local artists to undertake a large scale mural.
While the council may initially be sceptical of such a proposal, it was noted over several hours observing patterns of movement on site that the existing podium and steps act as a natural barrier which pedestrians actively avoid – the proposed compound would not interfere with the main flow of pedestrians in the area.
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Location Advantages Disadvantages Third Parties
SITE COMPOUND and DELIVERY COMPOUND 1: Hoarded enclosure within private yard off Axe St.
Single point of access control for operatives and visitors.
Immediate proximity to works
Preferred location to service southern half of building.
No impact on general public or pedestrian safety
Requires suspension of 1no. accessible & 2 no. general parking bays.
Fire tender and carpark access to be maintained
Assume land is in ownership of client.
May involve liaison with other stakeholders including carpark management company.
DELIVERY COMPOUND 2: Hoarded enclosure on public square off Clockhouse Ave
Preferred location to service northern half of building, provided that hoarded enclosure can extend all the way to proposed hoist location
Highly visible location in the public realm
Council may be resistant to closure of section of public square, even though it does not impede main pedestrian desire line
Council licences
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2.0 Access to working areas at height and protection of surrounding areas
We are conscious of the sensitivities of working in a live, occupied, mixed use building, and have devised our approach to minimise the impact of our work. Fortunately, cladding works are low-impact compared to other forms of construction, giving rise to relatively little noise, dust and vibration.
By virtue of the multiple projecting balconies, mastclimbers are not considered suitable for this project and a designed scaffold will need to be erected to cover the entire clad area, with protective fans at second floor level. Given the absence of cladding on the lower levels, the first working platform can be located at second floor level, allowing the lower levels of scaffold to remain relatively open with reduced visual impact on the adjacent civic uses. Stanchions will all be boxed in at ground floor level.
Safeguarding to all areas of the works to provide protection to residents, workers/visitors of Café, library and Nursey the general public. This methodology will be revised outlining further safeguarding procedures once the scope has been fully defined.
Our key considerations around scaffolding and hoarding on the different facades of the building are summarised below:
NW elevation SW elevation SE elevation NE elevation
Scaffolding Entire elevation to be scaffolded. No working decks required at lower two floors. Localised tree pruning may be required subject to arboricultural advice
Two gable ends to be scaffolded. Highly visible location on civic plaza - monarflex desirable to maintain appearance. Scaffold stanchions to be boxed in at ground level. Protective fan at second floor level. Design of first floor library roof required to inform scaffold design
Entire elevation to be scaffolded. Special design to achieve span over carpark entrance. No working decks required at lower two Floors
Entire elevation to be scaffolded. No working decks required at lower two floors. Protection from vehicle impact required. Protective fan at second floor level required
Hoarding No hoarding generally to avoid blocking view of park. Hoarding required only if second delivery compound permitted
No hoarding to avoid blocking library and cafe.
Hoarding required to provide safe enclosure to site compound
No hoarding required once protective measures against vehicles are provided.
Licensing Council land – hoarding licence required.
Council land – scaffold licence required.
Assumed mix of council land, land in ownership of BCMC. Potential oversailing of third party land (Emil church)
Delivery yard, likely to be private land – third party consent required
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3.0 A Grid line system is proposed to ensure building sections are left uncovered for the minimum possible time.
The stacking nature of the accommodation means that the vertical firebreaks between adjacent apartments align throughout the building. These firebreaks make for logical breakpoints in the works to remove and reinstate the cladding.
We have broken the building into 12 sections, each terminating at an existing vertical firebreak. Both cladding and insulation will be removed simultaneously to avoid an increased fire risk during the works.
The works will start in the north-west corner and proceed in a clockwise direction from gridline to gridline and from top to bottom as shown on the marked up elevations. The work gang stripping the existing material will have a short headstart, but they will only commence to open up the next grid section when the installation teams have reached the lowest floor of the previous grid section.
This means that only one section of the façade grid is left exposed to the elements at any one time to maintain both the operational and physical integrity of the building. Each grid section – from initial strip to completion – will be completed in under two weeks – the external wall of any individual flat should be exposed for only a matter of days due to the floor-by-floor approach adopted.
Commencing with the north elevation will allow the scaffolding (and the potential second delivery yard) in the public square to be removed once the first 5 sections have been completed, further reducing the impact on the public.
The effect of the second delivery yard would be to reduce the time to complete the first 5 sections by reducing the manual handling of material and accordingly the amount of foot traffic passing apartment windows on the opposite side of the building.
Should opening up works identify that it is necessary to remove the existing sheathing board, the implications for our workers, but more especially the residents, are increased. In this circumstance, we would structure our teams into small, responsive units, working in a rapid sequence to remove bracketry, cut the EPDM, demount and set aside the window, remove the sheathing board and install new, and reinstate the window. The aim is that every flat is left weathertight each evening.
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4.0 On site testing and recording of uncovered works.
For the avoidance of doubt, we understand this question to refer to the testing and recording of the existing fabric of the building.
The key questions on this project relate to the material, condition and consistency of the underlying sheathing board and SFS System, the dimensional and structural capacity of the existing bracketry to support the proposed system, and the condition of EPDM to all window openings uncovered by our work along with the overall fire strategy of Building external fabric.
Given that sheathing boards are seldom identifiable by branding or attached labels, the only way to definitively assess its fire resisting properties will be to take physical samples for testing via a crucible combustion test. This test will allow the rating of the existing material: A1, A2, B, or worse, to be ascertained. Physical samples will be taken from secondary exploratory works to the North-East Elevation. This will be dependent on the U-Value calculations, and the possible need for insulation to be filled with the existing SFS, therefore the sheathing board will be required to be replaced.
Presuming that design and technical review deems the bracketry suitable for reuse, pull tests may need to be carried out to a representative sample of brackets to ensure that the fixings are continuing to perform in accordance with the original design requirements and in line with what is needed for the new loading. Test locations will be recorded and added to the QCS for future reference.
The sheathing board will be spray-marked with an identifying number for each floor and gridline, and a full photographic record will be made of all areas in their opened state, which will also record the condition of existing EPDM to windows and any retained bracketry. This will form the first entry in our Quality Control System for each section of the building.
QUALITY COMPLIANCE
Guildmore uses a web based document management system which allows effective sharing of information and document management for the whole integrated project team. Our bespoke Project Quality Management Plan (“QMP”) and quality control documents form the basis of our tool-box talks with the trades, and are the tool by which our site teams can then inspect the quality and compliance of the work of each trade.
Within the QMP we clearly set out roles and responsibilities for the works.
Our success in quality control during installation thus reducing defects is based on the use of comprehensive Test & Inspection Plans (TIP)/Programmes and sign off sheets for each trade.
TIP’s are utilised for each activity together with sign off sheets (“QCS”) for each trade in each unit, with dead testing and completion testing and commissioning certificates. In the event of non-compliance, the sign off sheet is not issued and a correction notice is issued instead.
These quality control sheets / documents are developed specific to the actual build rather than generic quality control – Actual images and details are taken from the design drawings and inserted into the QCS with specific materials listed to ensure compliance.
These sheets cover each trade including areas such as fire stopping and compartmentation works which are of particular importance and includes supportive checklists and photographic evidence before closing up.
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Example Quality Control Sheet – Fire Stopping on Cladding Replacement Scheme
The QCS is firstly a communication tool, which translates what the design wishes to achieve into what the operative actually needs to know whilst also forming the basis for training of operatives in the specific requirements of the project, via tool-box talks and a personal laminated hardcopy.
As part of our quality culture and process, we also undertake regular audits and reviews at both site and senior management level as works progresses.
Engaged Supply Chain
During construction, our site teams chair weekly progress meetings with supply chain partners in accordance with a detailed agenda which has been developed over several years. Empowering our site team to manage subcontractors in a proactive rather than reactive manner has achieved demonstrable improvements in build quality and defect reduction.
These meetings are supplemented by regular tool box talks that take place with each trade’s foreman to ensure close understanding of project requirements and to communicate agreed solutions to problems which may be encountered. This approach is supported by daily inspections and regular audits.
Audit Regime
Our Quality Management Plan will identify our daily, weekly and monthly inspections and audits. Upon appointment we will agree frequency of inspections with your nominated Quality Control Inspector.
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5.0 Liaison with Employer team throughout the works
The site will be managed by a resident Senior Project Manager with the assistance of a Site Manager, who will manage daily activities such as deliveries, logistics, waste, safety matters and the co-ordination of subcontractor activities.
They will be supported by our Head of Facades and Cladding, who will attend site at least weekly, including all subcontractor review and monthly client meetings. Site team compliance with our approved quality system will be subject to monthly audits by our Health, Safety, Environment and Quality officer.
Our Senior PM will be responsible for all day-to-day liaison with the Employer project team throughout the project, and will prepare the monthly project report for issue to the Employer team. The outputs of our QCS system, including photographic recording of all areas at all stages, are shared with the client and include in the O&M manuals for future reference.
Should matters arise which require escalation or senior level input, our Head of Facades and Cladding will be available to discuss or meet the Employer as required.
Reporting processes and procedures will be agreed during the second stage and we already employ a collaborative information system to aide communication and ensure everyone has access to the right information at the right time.
