INCA Case Study: Hill Quays, Manchester

A large-scale recladding project full of intricate spaces that exemplifies the successful integration of advanced external wall insulation systems from Wetherby Building Systems Ltd.

Hill Quays is a premier residential development in the heart of Manchester, an area known for high demand for residential properties. The project comprises two interconnected buildings, Block A and Block B, connected via delicate bridges totalling nearly 3500m². The buildings house a total of 266 apartments, ground floor office units, and basement parking. Block B, featuring 42 luxury units with superior views and layouts, was the focal point of the remediation efforts.

Hill Quays benefitted from being one of the first projects to be funded by the Building Safety Fund utilising a Wetherby EWI system. The Building Safety Fund (BSF) provides funding to fix life safety fire risks associated with cladding in buildings over 18 metres high. 

The primary objective of the project was to replace and upgrade the existing system with a like-for-like design A2-rated system, enhancing safety, fire performance, and durability without compromising thermal efficiency. Although the client requested a U-value of 0.28 W/m²K, the project exceeded expectations, achieving an impressive U-value of 0.24 W/m²K.

Prior pull out tests ensured that all fixings met a minimum pull-out of 1.0kN, with various fixing types and sizes used based on insulation thickness.

Following extensive testing of the existing system, a Wetherby Direct Fix System was specified for the project as the best solution to providing a robust and versatile system for the desired traditional/modern look, which would also provide superior safety for the residents and workers.

Wetherby recognised installer and North West-based render and cladding specialist, Springforward Management Ltd, were appointed to install the Wetherby system, with Cobe Consulting Ltd as the main contractor. The system, rated A2-s1,d0 in accordance with BS EN 13501-1, features ROCKWOOL Stone Wool insulation, renowned for its exceptional fire performance. This high-quality Stone Wool insulation was installed in varying thicknesses to meet specific project requirements.

The building posed two challenges for this project. Firstly, the client initially intended to replace only the insulation outwards; however, comprehensive data for the original sheathing board was unavailable. In response, Wetherby developed new specifications utilising WeatherKem Calcium Fibre Cement Board to sheath the steel frame and masonry substrate. The WeatherKem board, an A1 non-combustible building board, is a regular component of the Wetherby EWI system.

ROCKWOOL Stone Wool Insulation was then directly fixed to the board and into the studs or areas of masonry substrate, presenting the second challenge. The building featured a mix of steel frame and brickwork, thin columns protruding, intricate spaces, and isolated areas that required varying insulation thicknesses to achieve the desired look. Consequently, different systems with thicknesses of 30mm, 40mm, 50mm, 60mm, and 90mm were used to maintain consistent U-values throughout the building. Managing the large quantity and various thicknesses of insulation on site was a challenge in itself.

The Insulation was topped with K+A Basecoat ensuring a seamless and high-quality base, then finished with Wetherby 4S Render. Wetherby 4S render (also known as Four Seasons Render) is a premium silicone render. 4S Render can be applied at 1°C to 30°C, and relative air humidity of up to 95%, increasing the application days available. Perfect for the unpredictable UK weather.

The success of the Hill Quays recladding project is attributed to the seamless collaboration between Wetherby Building Systems, Spring Forward Management, and Cobe Contracting Limited. Each stakeholder played a crucial role in ensuring the timely and efficient completion of the project, showcasing a commitment to excellence and innovation in construction. While the project didn’t provide a transformation of U-Values, the project exceeded all expectations of what the client requested.