Our aims:
- To bring a Modern Method of Manufacture (MMC) to Spain. The MMC concerns
Timber engineering, manufacture, supply and erecting of Timber Frame properties.
- To promote this globally preferred method of construction throughout Spain,
Portugal and other specified key areas in Europe.
BRIEF
Timber Frame buildings account for 70% of all low rise (up to 7 floors) new-build construction throughout the developed world. The buildings can be single affordable units, ranging through Apartment blocks, Hotels, Schools, Public and Leisure buildings – in fact any building can be of timber frame construction. This method of building has been used for centuries and now provides a fast and economical option to traditional materials.
ENGINEERED OPTION
Timber frame provides the load-bearing element for any building and intermediate floors are constructed from engineered joists, such as Eco-Joists or I-Beams. Roof superstructure is also an engineered product called Trussed Rafters. Several different types can be incorporated; therefore any configuration of roofscape is possible.
TIMBER FRAME
Any property can be finished in a chosen material, usually Stone, Bricks, Render or Timber or a combination of the materials, anything can be used provided it is acceptable to the local authority controlling the project. Once a design is agreed, the drawings for the project are given to us and we produce a set of structural calculations that dictate the building design in Timber Frame, (see attachment 1). Several important issues are considered such as point and spread-loadings, historic weather patterns for each individual location, earthquake resistance required and building use. The calculations allow for the buildings integrity under extreme conditions. The calculations are then given to our designers, who using a ‘stand-alone’ software programme design, the timber frame panels, Trussed Rafters and flooring requirements. All the components are manufactured in our factory, delivered to site and erected by our experienced teams.
CONSTRUCTION
Others construct a traditional or specified foundation in collaboration with us and we affix a soleplate, being the footprint of the subject building. The timber frame external walls are erected along with the internal load and non load-bearing and flooring cassettes plus the roof superstructure. An average 4 bed 130m2 property would take 4/5 days to erect. Thereafter the roof and window/external door installation takes place making the construction wind and weatherproof, this whole operation should take no longer than 8-10 days. As soon as the ‘envelope’ is sealed, the 1st fix Plumbing and Electrical installation commences and because all the components are at this stage open, this is a very fast process and again should not take longer than 2 days to complete. Next insulation is placed in the inside of the timber frames (150mm) and then plaster-boarding commences. Simultaneously the external skin is added, leaving a min 50mm air cavity. At this point the project would have taken around 4 weeks. Upon completion of the plaster boarding, joinery commences along with tiling and final fix plumbing and electrical installation. We allow a 12-week build programme, although we have clients in UK who regularly complete within 8-10 weeks.
ENVIRONMENT
All timber used by us is purchased from replenishable sources and is in a EU approved ‘chain of custody’ PEFC certificated system. We only use Pine-Spruce-Fir grown for purpose from Northern Europe, Canada or Russia. Each year we produce 252m cubic meters more than we harvest, and this means a new area of 3,500sq miles, roughly the size of Cyprus is planted each year.
Timber is effectively carbon neutral and has the lowest CO2 cost of any other commercially available building materials. Also strength for strength, Concrete requires five times and steel six times more energy to produce than Timber.
BENEFIT OF TIMBER FRAME V TRADITIONAL CONSTRUCTION
Apart form the obvious building cost and time saving elements, fuel requirements are substantially lower in Timber Frame houses, with an average U value of 0.27 W/m2K or less. This is achieved using low cost commercial insulation, installed to a pre-designed plan, and also allows a clear cavity, which prevents damp and interstitial condensation problems.
Passage of sound within any property can also be determined prior to construction, using Robust Detail principles and an all over ‘travel level’ of 48dB is easily achievable – unheard of in Spanish homes. Two problems occur regularly in traditional Spanish buildings and they are:
- Cold and damp conditions internally as a result of the absence of insulation and cavity walls, in winter months.
- During hot weather, the walls and roof heating up during the day and cooling within at night, effectively causing a huge radiator, requiring mechanical assistance to cool the rooms to an acceptable level.
None of the above can occur in Timber Frame homes. In several countries any air leakage is not permitted and each building must be tested. Again, using the principles of Robust Detail Timber Frame has no problem passing any tests. It should also be noted that Timber Frame buildings, if built under the Robust Standard Detail in the UK are exempt from any sound testing, which is compulsory for any other method of construction.
Note: All timbers used by us MUST be Stress Graded to C16min, Kiln Dried and Vac-Vac treated for Wood-boring Insect and Ingress of moisture that may cause rot.
MANUFACTURING REQUIREMENTS
It is important to remember that storage is an important part of the Timber Frame manufacturing process, therefore some thought should be given to external area as well as manufacturing space. Because Timber Frames can be exposed to the elements for a safe period of 14 weeks external storage is the norm in our industry. Initially a manufacturing unit of between 600 and 1000 m2 would be required with another similar sized area externally for parking and storage.
MACHINERY
*The basic machinery to commence operations would be:
2 x 350mm or 400mm Cross-cut Feeder Bench Saws. £ 4,000.00
1 x Wall Panel Saw. £ 3,000.00
1 x Table Panel Saw. £ 2,000.00
1 x 450mm Rip Saw. £ 1,500.00
1 x Compressor and lines/guns £ 1,500.00
Eco-joist Press and Software £25,000.00
Truss Rafter Presses and Software £35,000.00
1 x Transit Type Crew Van. £ 8,000.00.
£79,000.00
OFFICE
Furniture £ 4,000.00
3 x Computers £ 2,000.00
Plan Copier £ 2,000.00
Printers, Fax £ 1,000.00
Staff Welfare Facilities £ 3,000.00
Training Courses £ 5,000.00
Installation Costs £ 5,000.00
£22,000.00
* Priced in UKP as all above are readily available in UK although transport costs would have to be added if the items are not available in Spain.
STAFF LEVELS
Although all key staff are in place, we would seek to train others in different key roles and employ and train all local individuals. The initial requirement would be:
Factory/Site
Trainee Factory Manager 1 person – new appointment
Factory machinists 2 persons – new appointments
Factory Bench Hands 4 persons – new appointments
Driver/Yardman 1 person – new appointment
Labourer 1 person – new appointment
Site Erectors 3 persons – new appointments
Office
Trainee Manager 1 person – new appointment
Receptionist/Bookeeper 1 person – new appointment
Internal Sales 1 person – new appointment
Trainee Estimator 1 person – new appointment
Trainee Contracts Manager 1 person – new appointment
The overall annual budget for staff wages would be 250,000 Euros.
Overhead and running costs are not discussed here.
TURNOVER
The turnover envisaged in the first full years trading is 1,000,000 Euros, although a target of 1,500,000 Euros will be set. Rapid growth is predicted as new European laws and regulations governing carbon emission, health and safety, passage of sound and construction materials are due to come into force and traditional materials and methods will not be able to meet the new demands. USA and GB have raised the standards to a very high level and where it is still possible to build using traditional materials and methods, the costs are around 35% higher than a timber frame construction. Attached (2) are the advantages of using Timber Frame as a preferred method over Concrete for a constructor and also attached is an illustration of several benefits of buying a timber frame home for an occupier.
GENERAL
There is no doubt that Timber Frame is the future for Spain and Portugal and because of its global acceptance, it is only a question of time before MMC is adopted as the main route for general and specialist construction. The writer and his colleagues have conducted in-depth research over the past two years in Spain and are very confident that our systems will be accepted as low-cost affordable and social housing by many local authorities throughout Spain. A home that is affordable to most people by way of purchase or rental combining the latest construction technology and can be occupied in weeks rather than months, can no longer be ignored. Because MMC is a complete kit and erected on site, around 90% of self-builders choose Timber Frame systems, because of the above reasons. Self-managed house building should be encouraged in Spain as homes can be built for a fraction of the current prices.
The main question we are asked is “How can you tell if a house is timber framed”? The answer is – You can’t, the only people who know it is, are the builder and the occupant who enjoys a comfortable, low cost home.
The UK government builds over 60% of it’s social housing stock in MMC and has decreed that ALL the 2012 Olympic buildings MUST be MMC. – Spain will follow!