INCA Case Study: Accrington Academy

Project Overview

At the heart of K Systems’ mission is the delivery of high-performance, future-proofed building envelope solutions that elevate standards of safety, durability, and design.

K Systems, working in partnership with approved installer Profac, undertook a significant remediation project at Accrington Academy to upgrade the external wall insulation (EWI) system and improve the fire safety and aesthetic performance of the building.

This complex project involved replacing the existing Expanded Polystyrene (EPS) insulation with non-combustible mineral wool and applying a high-performance render system, all while navigating the challenges of working in a live school environment.

Background to the Project

The existing façade of Accrington Academy was fitted with EPS insulation, which, while compliant at the time of installation, no longer met the evolving fire safety regulations.

In a proactive move to future-proof the building, a remediation programme was initiated to upgrade the system to a safer, more robust solution.

The school remained operational throughout the project, requiring careful planning and collaboration to ensure safety and minimise disruption.

Construction Challenges

One of the most significant challenges was delivering the remediation in a live educational environment.

Profac, K Systems’ approved installer, worked closely with the Academy to ensure the safety of students and staff at every stage. Drilling and fixing activities were restricted to specific times outside of classroom hours to avoid disrupting classes, with a large portion of the work carried out during weekends and carefully scheduled periods aligned with the school timetable.

Additionally, the project involved working with an existing substrate of sheathing board on a steel frame, something which resulted in significant cost savings for the Academy and allowed for budget maximisation.

K Systems conducted detailed pull-out tests and assessed the integrity of the sheathing board to ensure the correct fixing solution would provide long term durability.

The bespoke soffit detailing, incorporating a combination of adhesive and mechanical fixings, showcased K Systems’ commitment to structural integrity and long-term system performance. Careful attention was given to the finishing around lighting and the supporting struts, resulting in a clean, professional appearance. Throughout the intricate installation process, K Systems’ technical team provided tailored, project-specific support, ensuring a seamless and high-quality outcome.

Specified System and Its Benefits

K Systems Direct Fix M (KIWA certified) was specified for this project. The system featured 100mm of A1 non-combustible mineral wool insulation and a silicone TC render finish.

This specification achieved several key objectives:

• Fire Safety: Upgraded the fire classification from B-s1,d0 to A2-s1,d0, significantly improving the safety of the building’s façade.
• Weather Resistance and Flexibility: The TC15 silicone render provided UV stability, robust weathering protection, and flexible performance.
• Aesthetic Excellence: The crisp, clean finish of the silicone render, combined with refined detailing at the soffits, window reveals, and parapet junctions, delivered a visually striking and modern façade.

Neat detailing around façade lights, soffit struts, sills, and glazing louvre fins ensured a seamless appearance.

The use of compriband tape and silicone sealant (primary and secondary sealants) created a robust connection between the EWI and existing building elements, such as brickwork and roof parapets to prevent ingress and resist wind driven rain, ensuring longevity of the façade.

End Result

The completed installation has transformed the visual identity of Accrington Academy, particularly its front elevation, which now presents a clean, modern, and professional appearance as visitors approach the main entrance. The combined use of silicone render, glazing, louvres, and brickwork creates a harmonious blend of materials and a striking architectural impression.

More importantly, the new system enhances the Academy’s compliance with modern fire safety regulations and improves the building’s thermal performance – ensuring a safe, warm, and visually pleasing learning environment for years to come.

Client Testimonial

“Delivery of the project required teams to work seamlessly together and have absolute trust in the other’s skill, vision, and judgement. That is what we had with K Systems and Profac on the Accrington Academy project – particularly the installation of the external wall insulation system.

“The use of non-combustible mineral wool insulation provides an upgrade to current building regulations. The new silicone render provided a fresh finish to the entrance and front of the academy. Care and attention were allowed for the educational environment and a successful remediation installation was achieved.”

— Andrew Walton, Facilities Manager, Accrington Academy

Why K Systems?

This project exemplifies why K Systems is a leading manufacturer in the EWI sector, highlighting credentials such as:

• Regulatory Expertise: Proactively upgrading systems in line with the most stringent fire safety standards.
• Trusted Technical Advisors: Conducting full pull-out testing and designing bespoke fixing solutions to suit complex substrates.
• Design-Led Thinking: Creating visually impactful facades without compromising performance.
• Collaborative Delivery: Ensuring installation works around the needs of live, sensitive environments.

The success of the Accrington Academy project is a testament to K Systems’ commitment to delivering high performing EWI systems with a key focus on fire safety, aesthetics and thermal comfort.