Project leaders from Allford Hall Monaghan Morris (AHMM), Eckersley O’Callaghan, Lindner Prater, and Schüco discuss the collaborative processes and technical challenges behind the multiple façades on the acclaimed Norton Folgate development in London, with AT’s Technical Editor John Ramshaw.
In association with
At the heart of most successful façade designs is a story of collaboration, teamwork and ingenuity. In this new technical series, sponsored by Schüco, we explore these important and revealing processes through a standout project submitted for the 2024 Schüco Excellence Awards. The first article examines the Norton Folgate development in London, masterplanned by AHMM (with Stanton Williams, Morris + Company, DSDHA, and East), in collaboration with façade engineer Eckersley O’Callaghan; specialist façade contractor Lindner Prater; main contractor Skanska; and façade, window, and door solutions provider Schüco.
Six plots, four architects, one masterplan
The development is set within the Elder Street Conservation Area, located between the City of London and Shoreditch in east London. Masterplanned by AHMM, the BREEAM Excellent-rated scheme combines both new and refurbished commercial and retail buildings designed by four practices: AHMM (Blossom Yard & Studios, Nicholls and Clarke, and Loom Court), Stanton Williams (Elder Yard & Studios) Morris+Company (15 Norton Folgate), and DSDHA (16 Blossom Street).
The design team adopted a building-by-building approach to the retained structures, including the Blossom Street Warehouses, Elder Studios, Loom Court, 16-19 Norton Folgate and 5-11a Folgate Street, focusing on sensitive restoration and remodelling, as well as façade retention. The new-build elements, including Blossom Yard & Studios and Nicholls and Clarke, employ robust, high-quality materials, such as brick, terracotta, and aluminium windows and doors.
View looking along Shoreditch High Street with Nicholls and Clarke in the foreground, and Blossom Yard & Studios adjacent.
Façade engineer Eckersley O’Callaghan, alongside Skanska, developed a procurement strategy for the entire site, ranging from unitised curtain walling on Nicholls and Clarke, to prefabricated masonry facades on Blossom Yard & Studios and Elder Yard & Studios, a combination of traditional hand-laid brick on 15 Norton Folgate, and reclaimed brick refurbishment on multiple historic warehouses.
Central to both the new-build and retained/reworked façades are a wide range of Schüco systems, including USC 65 unitised curtain walling (Nicholls and Clarke); FWS 50 and FWS 60 stick curtain walling (multiple buildings, including Blossom Yard & Studios); AWS 70 WF.HI windows (Loom Court); ASE 60 and ASE 80.HI sliding doors (Loom Court and 16 Blossom Street); ADS 70 doors (multiple buildings); and ASS 70 FD bi-folding doors (Elder Yard & Studios).
Designed by Morris+Company, 15 Norton Folgate comprises both refurbished and new-build elements.
Establishing a common façade language
The variegated character of the site, together with the presence of ten existing buildings, led the four architectural practices to adopt brick as the primary façade material across the entire scheme. “This decision was also about rejecting the glass architecture of the City in favour of the historic character and grain of the conservation area context,” explains AHMM director Laura Stephenson. Having made this decision, each practice adopted different types of brick in order to reinforce the character of their own individual buildings. “The practices spent a lot of time before and after planning with their brick samples; looking at them together across all the plots, to ensure they worked in harmony with each other,” says Stephenson.
In common with Blossom Yard & Studios, the brick façades of Stanton Williams’ Elder Yard & Studios make extensive use of design for manufacturing assembly (DfMA).
Working up the design
The façade designs for Blossom Yard & Studios and Elder Yard & Studios were originally based on traditional hand-laid brickwork, but façade engineer Eckersley O’Callaghan, among others, pushed for a design for manufacturing assembly (DfMA) approach. This was embraced by the main contractor Skanska, and ultimately the client, British Land, who could see that the capital uplift of DfMA would be paid back through benefits in programming, welfare, logistics, and build quality.
“The move to DfMA was a really interesting technical challenge for us,” recounts AHMM associate director Peter Mayhew. “We ended up working with Thorp Precast, but they came on board quite late, so we actually already had piles in the ground and all our loadings were set.” As a result structural engineer AKT II, together with Eckersley O’Callaghan, Skanska, and Thorp Precast, had to conduct extensive analysis to prove that the offsite façade solution was feasible.
After considering a range of different DfMA options, the team chose a ‘donut’ panellised system utilising ultra-high-performance concrete (UHPC) finished with 50mm brick slips, pre-glazed with the Schüco system offsite. This design approach greatly reduced the overall weight of the façade. “There was a really challenging timeframe in which to implement this change,” says Mayhew. “And the way we were able to do it was that everyone essentially trusted everyone else.”
“Eckersley O’Callaghan’s technical expertise and experience of working with precast panel systems really helped us understand what was and wasn’t possible,” continues Mayhew. “They’re very helpful and knowledgeable, and worked closely with us in developing sketches and ideas and so on. Thorp Precast were also super helpful and proactive. They’re interested in applying their systems to challenging projects, so they were also really good to work with.”
The prefabricated façade of Blossom Yard & Studios employs ultra-high-performance concrete (UHPC) and 50mm brick slips.
Both AHMM and Stanton Williams worked closely with Eckersley O’Callaghan to finesse the detail design elements. Particular attention was paid to panel joints in order to ensure a hand-laid brick aesthetic; and the panel brackets to maximise concealment across the façades. The team decided to employ traditional masonry on the ground floor areas to avoid the possibility of damaged panels, and to maximise the authenticity of the brick aesthetic.
“It took a huge effort from the whole team and a highly curated design programme to convert the design from handmade brick to prefabricated panels,” comments Eckersley O’Callaghan director Hugh McGilveray. “We mapped out a week-by-week pre-contract services agreement (PCSA) period with Thorp, including workshops and specific deliverables, over an intense two-month period to ensure viability. Once this had been achieved, we had another highly consolidated period where we released batches of drawings on a timeline that Thorp could respond to.”
Quality control
The adoption of offsite manufacture enabled the façade team to investigate and refine the design through a full-scale mock up produced by Thorp Precast. Further refinement and quality control took place on an inspection of production panels later on. Working alongside Thorp Precast, window installation for the prefabricated panels also occurred offsite and was undertaken by Lindner Prater. “They [Lindner Prater] brought a high degree of technical knowledge to the project, making sure that the interfaces between the precast and the windows were resolved to a point where there wouldn’t be an issue,” says Mayhew. Onsite erection of the panels was carried out by Thorp Precast and overseen by Skanska.
A rigorous process of benchmarking took place during and at the end of construction, with the façade panels viewed from different ‘real-world’ vantage points. “We took a pragmatic approach to quality informed by the way people will actually see and use the building in everyday life,” explains Mayhew.
The Nicholls and Clarke combines Schüco USC 65 unitised curtain walling in combination with vertical aluminium ‘baguettes’.
The manufacturer’s perspective
Schüco façade systems feature across the development – not least on Nicholls and Clarke, which combines USC 65 unitised curtain walling in combination with vertical aluminium ‘baguettes’. The company’s engagement with AHMM began in 2014 at the pre-planning stage, where it provided guidance to the project team on façade systems that would not only meet the commercial brief, but also key aesthetic demands, and the relevant building standards.
After working closely with specialist façade contractor Lindner Prater, Schüco presented its proposed façade solution for Nicholls and Clarke to AHMM, the client (British Land) and cost consultant (Turner & Townsend alinea). “The presentation ran through the USC unitised systems, which included eight different profile and gasket dies, as well as interface details with the aluminium cladding, and the installation process itself,” explains Schüco National Specification Manager Stephen Newell.
Following design approval, the manufacturer produced thermal calculations and project-specific drawings. Among the challenges was ensuring that glass replacement was possible in terms of the large panel sizes, availability of fixing points, and proximity/location of the aluminium baguettes. “By engaging early on with the third party supplier we were able to spot any potential issues that may have impacted on design, installation and cost,” says Newell.
Lindner Prater’s familiarity with Schüco unitised products, and its long association with the manufacturer, meant that the installation phase progressed smoothly. Looking back, Newell says, “early collaboration combined with high levels of quality control ensured that the finished façade met all the requirements of the original 2014 brief.”
The Nicholls and Clarke with Blossom Yard & Studios adjacent.
The specialist façade contractor’s perspective
“As the appointed specialist subcontractor for the glazing, cladding, and roofing packages, we worked closely with Skanska to ensure the seamless integration of Schüco systems,” explains Shane Blackett, Head of Procurement & Supply Chain at Lindner Prater. “Our scope extended to both the retained buildings and also the construction of six new buildings spread across the six plots. Our works encompassed a wide array of façade elements utilising Schüco glazing systems, unitised curtain walling, stick curtain walling, windows, single- and double- swing doors, sliding doors and bi-folding doors along with extensive rainscreen cladding.
The involvement of multiple practices presented a challenge for the specialist façade contractor in respect of the design and approval process. “This unique challenge was recognised in the early stages of the project between Skanska and ourselves,” says Blackett. “We both agreed a full-on collaborative approach would be a minimum in order to seek efficiencies and bring added benefit to the project.
A cohesive project team, along with coordinated decisions among all stakeholders, played a pivotal role in maintaining the project timeline. The implementation of off-site fabrication and just-in-time delivery, optimised on-site efficiency and minimised disruption. Materials were procured upon design acceptance and transported to an off-site facility, enabling site teams to access them as needed for timely deliveries.”
Contact Details
For more information, please call 01908 282111, email, or visit the Schüco website.
