INCA Case Study: Charrington Court, Essex

This innovative cladding remediation project exemplifies excellence in fire safety, resident engagement, and sustainable building practices.

Charrington Court is a high-rise residential building in Essex that underwent significant remediation to replace combustible cladding and insulation following a detailed inspection. The project was initiated by One Housing Group (now part of Riverside) in response to fire safety concerns.

In 2020, an EWS1 inspection revealed that the as-built information did not match the installed materials, which included combustible cladding. This prompted a comprehensive remediation project to replace the façade material finishes, soffit cladding panels, and vertical balcony privacy screens with non-combustible alternatives.

An innovative approach to this challenging remediation project was required, prioritising high levels of communication with residents.

The remediation requested by the client, aimed to replace the existing façade with an A2-rated system that matched the current finish, colours and to achieve the same U value of 0.18 W/m²K. This effort was a collaboration between Wetherby Building Systems Ltd, United Living, MK Facades and Rockpanel Cladding. Wetherby supplied the Wetherby Cavity Rail System, featuring Brick Slip and Render finishes, while Rockpanel provided fire-resistant exterior cladding boards

At the beginning of the project, the Wetherby Technical team conducted pull-out tests to assess the strength and security of the fixings into the substrate. The tests focused on at least 15 fixings distributed across the building and at various heights to ensure consistent results. Wind-loading calculations were also performed to confirm the system’s suitability. These calculations were then reviewed by Wetherby’s Technical Director to determine an appropriate fixing pattern, which was subsequently included in the installation specifications.

The building comprised multiple substrate types, necessitating the specification of various Wetherby systems to achieve the desired results. Recognising the expertise of contractor and INCA member MK Facades, Wetherby approached them to install the systems, leveraging their extensive experience with Wetherby systems.

The building primarily features a steel frame, with the ground floor constructed using a masonry substrate. In this project, 160mm ROCKWOOL Stone Wool Insulation was installed, fixed to 25mm Wetherby Ragrails to create a cavity. Stone Wool Insulation is chosen for its superior fire-resilience, thermal efficiency, durability, and full recyclability, making it an excellent fit for Wetherby EWI systems.

The proposed building faced obstacles due to uneven substrate. To address this, Wetherby specified double boarding the insulation in certain areas to level the exterior before MK Facades applied the Wetherby Silicone ‘K’ 1.5mm textured finish.

Luckily, Wetherby’s Silicone Render finish already has a flexible anti-crack formulation and ultra-violet resistant pigments. Wetherby Alkali Resistant Scrim Cloth (mesh) was incorporated into the top third of the Wetherby K+A Scrim Adhesive to provide extra strength to the façade system.

The unrivalled versatility of the Wetherby silicone thin coat render system allows the products to be specified with confidence to transform virtually any substrate, giving dull and tired looking structures a new lease of life. Wetherby offers an exact match service so the desired render colours of 050 Y 10 R & 7500 N could be achieved to replicate the previous façade.

All large-scale urban development projects come with their own set of challenges, and Charrington Court was no exception. The teams developed a customised and highly adaptable work system to ensure minimal disruption to residents while upholding the highest operational standards.

Due to the projects restricted footprint and limited storage space for materials, including cladding panels, an innovative approach was adopted to material movement and the site implemented a just-in-time delivery program. This strategy minimised the need for on-site storage and eliminated the time spent sorting materials such as large insulation boards and render tubs on site.

The project has received exceptional feedback from residents for the high quality of works, effective communication, and the overall delivery of the project, ensuring their safety and satisfaction.

United Living operated a fantastic open-door site office, so residents with queries could access staff anytime. The entire programme of works was posted in all communal areas, and their dedicated Resident Liaison Officer engaged closely with residents before work was carried out and supported them throughout to avoid uncertainty and disruption.

The Building Safety Act provides clear guidelines for improved data management and documentation of building work. All partners worked closely together and with clients from the design and construction stages to thorough record-keeping and evidence documentation, ensuring a comprehensive and continuous flow of information.

Collaboration and partnership working are essential in this sector, and the Charrington Court project is an example of how true partnership can deliver excellent results.

Michael Gallagher, Mobilisation Manager (Cladding), One Housing Group (Riverside)

“Bringing together our combined strengths and expertise has ensured that we have delivered excellent results on this multimillion-pound project to ensure that residents remain safe and warm in their homes.”