Verbus System Design Manual
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The document is a design manual for the Verbus modular construction system. Some key points: - Verbus uses a modular construction approach where buildings are assembled from prefabricated modules for faster construction. - Modular construction can reduce construction times by 60% and on-site labor by 70% compared to traditional methods. - The Verbus system is based on shipping container technology so the modules are robust and suitable for transportation. Modules have a steel frame and lightweight wall panels. - The design process involves an initial viability appraisal followed by concept design, detailed design, manufacturing, and installation of the modules.
Verbus System Design Manual
- 1. Verbus System Design Manual issue 003: March 2009
- 2. overview VERBUS > Significantly improved programme times compared to traditional construction. > Improved project costs. > Deliverable anywhere in the world. > Up to 16 stories achievable with a standard module. > Reduced on site project and commercial management required by Main Contractor.
- 3. CONTENTS 1 Verbus System > What is Modular Construction? > Why use Modular Construction? > How does Verbus differ from other systems? > Verbus Cycle 2 Verbus Process > The Team > The Design Process > Limitless Solutions > Modular Building Concept 3 Verbus Technology > Construction > Geometries > Structure > Assembly and H&S > Robustness & Durability > Fire > Acoustics > Thermal Performance > Heat & Ventilation > Sustainability > Standard Details 4 Verbus FAQ’s > Structure > Manufacture & Delivery > External Treatment: Roofing Facade/ Cladding > Glazing > Acoustic Design > Conservation of Fuel & Power - Thermal > Fire Safety > Drainage > Mechanical & Electrical > Internal FF&E > Resistance to Contaminants & Moisture > Toxic Substances > Stairs Lifts & Protection from Failing > Certification & Design Life
- 4. 1 Verbus System > What is Modular Construction? > Why use Modular Construction? > How does Verbus differ from other systems? > Verbus Cycle
- 5. VERBUS SYSTEM Modular Construction WHAT is modular WHY use modular construction? construction? Modular technology considerably reduces construction time. It is safer, quieter and cleaner than traditional methods of construction. It reduces the likelihood of defects and allows easy and low cost maintenance. It also offers designers The term modular construction and architects flexibility which is cost-effective. is used where a building is Modular construction has many benefits in terms of labour skills, programme and quality. National Audit Office assembled from a series of statistics: volumetric modules, linked together to form a complete 1.Construction times can be reduced by 60%, saving both programme time and associated preliminary costs. structure. The modules, which are manufactured, finished and 2.On-site Labour is typically reduced by 70% compared to traditional construction techniques, which leads to considerable benefits on site for access, storage of materials and Health & Safety issues in general. fitted-out off-site, under factory conditions, are then 3.The building envelope can be made water tight up to 80% faster than through traditional construction techniques, transported to the construction leading to reduced risks due to weather. site and lifted into place. All which lead to greater speed, productivity, quality and safety thus ensuring earlier completion and greater revenue generation. HOW does Verbus differ from other systems? The Verbus system is built around newly developed, patented technology, and is far more robust than any other system on the market. The Verbus system is based on the fittings and transportation characteristics of the universal shipping container hence Verbus modules are not only highly robust, versatile and economic but they are also highly suitable for both international and national sea and road transportation using conventional vehicle logistics. The Verbus system with its steel frame and panelised lightweight wall construction are particularly suitable for use as structural modules making additional steel framing unnecessary. The robustness and rigidity of Verbus modules also allows far greater variety in the type of finishing that can be applied to the exterior of the building and the quality and level of fit-out that can be introduced to the interior The Verbus system is generally self stabilising and does not require support from the staircases or riser cores, removing the construction of these items from the critical path. Finally the close integration and vast experience of the Verbus design team, logistics department and module manufacturer, mean that when initial concept schemes are considered, total optimisation can be built-in at an early stage.
- 6. VERBUS SYSTEM Verbus Building Cycle fabrication fitout shipping docking The Verbus System utilises established production techniques and capacity to manufacture quality accommodation solutions at high volume. The basis of the system is a range of High Strength, corrosion resistant steel manufactured modules fully certified, tested and approved that can be fully fitted out and combined to create a wide variety of building shapes and be adapted to suit any planning or end user needs. The Verbus System is also revolutionary in that it is fully de-mountable and re-usable. road transport dismantle completion connection installation re-furbish re-assabmle
- 7. 2 Verbus Process > The Team > The Design Process > Limitless Solutions > Modular Building Concept
- 8. VERBUS PROCESS The Team The Verbus Team provides full technical support and detailed information on all aspects of the Verbus Systems solution. Working closely with Client’s Team to ensure a seamless interface and a fully integrated building solution. Verbus Systems have worked closely with industry professionals to develop a highly versatile, efficient and r o b u s t m o d u l a r b u i l d i n g s y s t e m . Ve r b u s S y s t e m s c a n provide a full design and service to clients ranging from foundations to finishes. Working with contractors they can deliver and erect their patented volumetric modular system as a shell or fully fitted finish. Buro Happold have helped develop Verbus Systems design and technology over the last 3 years. This has been achieved through detailed design development of the structural engineering, fire, thermal and acoustic performance of the units in order to gain compliance with local building regulations. Initially the projects have been in the UK, but they are now being developed further for approval in other European countries as well as North America and the Middle East K KA h a v e a s s i s t e d i n t h e d e s i g n a n d d e l i v e r y o f numerous Verbus Systems projects throughout the UK and other worldwide locations. From inception to completion, through in depth understanding of the system, KKA can provide full design solutions or simply advise on developing the most economical Verbus solution.
- 9. VERBUS PROCESS The Design Process The Design Process Verbus Design Stages Stage 1A: Initial Viability Appraisal The Verbus Team provides full technical support and detailed Identify Client's requirements, propose multiple options to maximise use of Verbus Modular Units within the scheme. information on all aspects of the Demonstrate the flexibility with which the Verbus Modular Units can accommodate diverse layouts and multiple Ve r b u s S y s t e m s s o l u t i o n building types. ensuring a seamless interface between the Verbus System Stage 1B: Preliminary Unit Types and Layouts and all other building Prepare outline proposals based on clients preferred options including basic schedule on Units Types and Sizes. components. Liaise with Client Team to explain the fundamental principals of the Verbus System and its integration into a complete building solution. The Verbus Design Team can offer a full building design Stage 2: Detailed Unit Types and Layouts service, but where required will Prepare initial GA drawings including all setting out and structural parameters . work alongside the Client's Team Liaise with Client Design Team on all building interface issues and prepare generic information on Structural, M&E, through every stage of the Thermal, Fire and Acoustic performance of Verbus components. design process to ensure a fully Prepare detailed schedule of Unit Types, Sizes and Fit-out. integrated, optimised and statutory compliant building Stage 3A – C: Unit Shell and Structure Plans, Sections & Elevations solution is achieved. Prepare detailed Unit Shell fabrication drawings and carry out all structural calculations etc. in conjunction with Unit Shell. Early involvement of the Verbus Liaise with manufacturer to ensure fabrication drawings / specifications are optimized for Unit Shell construction and Team in the design of a building economy. leads to greater flexibility and greater economic and Stage 4A – D: Unit Fit-out Plans, Sections, Elevations & Schedules programme benefits. Prepare detailed internal fit-out drawings and schedules based on the clients Employers Requirements Documents for client approval and fabrication. The Verbus Team becomes a Liaise with manufacturer to ensure fit-out drawings / specifications are optimized for Unit Shell construction and fully integrated part of the overall economy. Project Team attending briefing, Prepare detailed M&E drawings and specifications for all services to be provided in Verbus fit-out design, and contractor / site Stage 5: Unit Interface / Co-ordination Remaining Building Fabric. meetings and ensuring a continuous flow of information Prepare all information necessary to ensure Verbus System can be integrated by Client Design team with all between all parties. remaining building fabric.
- 10. VERBUS PROCESS Case Study 1: The Design Process PROPOSED HOTEL VERBUS STAGE 1A OPTIMISATION STUDY VERBUS PROPOSALS TOTAL NUMBER OF BEDROOMS: 80 TOTAL NUMBER OF VERBUS STOREYS: 3 Staircase could be provided in Verbus unit. Note: careful co-ordination required. Traditional steel frame podium structure LEVEL 1 Corner could be provided in Verbus or traditional. Note: Half units are Option2: Greater economy as ORIGINAL PROPOSALS less economical than units are the same full units. To achieve greater economics, Junction will need consideration reduce number of where Verbus units intersect. types. Module Module Module Module OPTION 1 OPTION 2 LEVEL 2 - 3
- 11. VERBUS PROCESS Case Study 2: The Design Process VERBUS PROPOSALS Line of original tower. PROPOSED HOTEL VERBUS STAGE 1A OPTIMISATION STUDY TOTAL NUMBER OF BEDROOMS: 230 TOTAL NUMBER OF VERBUS STOREYS: 9 LEVEL 1 Building extended to rationalise the use of Verbus units. Keep corridor central if possible to maximise economy. All elevational modelling as “decorative” cladding/balconies etc. This ensures maximum off site fit out. ORIGINAL PROPOSALS LEVEL 2-6 Mix of rooms depandant on width of site. All elevational modelling as “decorative” cladding/balconies etc. This ensures maximum off site fit out. LEVEL 7
- 12. VERBUS PROCESS Case Study 3: The Design Process VERBUS PROPOSALS Ground and mezzanine floor levels to be traditionally constructed Dashed line indicates outline of upper floors. Extent of Bedroom accommodation over. PROPOSED HOTEL VERBUS STAGE 1A OPTIMISATION STUDY TOTAL NUMBER OF BEDROOMS: 70 TOTAL NUMBER OF VERBUS STOREYS: 5 ORIGINAL PROPOSALS GROUND & MEZZ LEVEL Proposed void space, will require fire stopping. Traditionally constructed bridging infill. Continuity of finishes maintained by lining of corridor wall face on site/ typical ‘zip-up’ detail. External cladding to face of all units by contractor. Standard Units arranged radially. LEVEL 1 - 4 RESIDENTIAL BY OTHERS HOTEL BY VERBUS Module can be delivered with staircase insitu. Module Module Module Voids for lift shafts. LEVEL 5
- 13. VERBUS PROCESS Case Study 4: The Design Process VERBUS PROPOSALS Traditional Frame Structure & Fit Out will be required to corners. PROPOSED STUDENT ACCOMMODATION: VERBUS STAGE 1A OPTIMISATION STUDY TOTAL NUMBER OF BEDROOMS: 740 TOTAL NUMBER OF VERBUS STOREYS: 20 Traditional Frame Structure & Fit Out will be required to corners and Braced Slightly Larger Units Corners. to accommodate Stair approx 200-300 mm wider than Standard Room. Thus Structure “Lines” through. Traditional Frame Structure & Fit Out will be required to corners. Possible Extra Rooms could be achieved. LEVEL 1-6 LEVEL 7 LEVEL 8 However Implication is 2no. 6 Bed Clusters. Traditional Frame Structure & Fit Out will be required to corners. ORIGINAL PROPOSALS Traditional Frame Structure & Fit Out will be required to corners and Braced Module Corners. LEVEL 9,10 LEVEL 11- 20
- 14. VERBUS PROCESS Limitless Solutions Variable length, height, width, orientation, juxtaposition, layout and finish construct endless design solutions and building layouts. Modular construction need not be limited by a single solution only your imagination. consider the time, cost & quality benefits of a fully finished modular building solution. 1 pre-fabricated frame pre-fabricated ground floor podium structure delivered to site for rapid assembly 2 building blocks fully fitted & finished room modules containing bedrooms, circulation & services accommodation “stacked” up to 15 storeys without the need for additional framing 3 modular roof fully finished roof modules pre-laid to fall & complete with gutter system fitted to the upper storey and integrated with pre-installed plant modules if required 4 “clip on” cladding modules are designed to be clad with an external skin, but can be delivered fully insulated and glazed, ready for habitation
- 15. VERBUS PROCESS Modular Building Concept pre- fabricated roof modules utilize modules lowered and bolted Verbus connection technology shipped in into place “batches” in the volume of a shipping module upper circulation module pre-fitted with lifts stairs pre-fitted in circulation ready to “drop” upon completion of vertical modules core modular cladding system as single component (where required) enhancement features can be attached before module is lifted into place option A. ground floor structure provided as traditional construction complete modular units craned into position option B. ground floor structure provided as a ready to assemble prefabricated “kit of parts” option C. ground floor podium structure provided in Verbus units with Verbus spacer signature cladding frames providing extra height if required system can be attached in module size sections before module is lifted into place
- 16. 3 Verbus Technology > Construction > Geometries > Structure > Assembly and H&S > Fire > Acoustics > Thermal Performance > Heat & Ventilation > Sustainability > Standard Details
- 17. VERBUS TECHNOLOGY Construction: The Basic Verbus Module The basic Verbus module comprises a “shell” of high tensile corrosion resistant steel components with composite wall, floor and roof structure that provides superior insulation for sound, thermal & fire performance.
- 18. VERBUS TECHNOLOGY Construction: The Basic Verbus Shell intermediate castings are introduced depending on unit size to ensure maximum flexibility for transportation lifting stacking & docking the module frame comprises lightweight folded plate rails and posts Composite roof comprises: - 1.6mm Corten steel flat outer sheet units are permanentlybolted/ - 100mm mineral wool insulation secured once on site via a simple bolt - “C” channel steel joists box - 9mm plywood - 2 layers of 12.5mm plasterboard openings are framed with closure posts & head & sill rails the frame is stiffened by lightweight 1.6mm gauge corrugated steel sheets i.e. the frame and outer sheet act as a lightweight diaphragm structure a grid of simple plates & standard industry connections are installed to ensure a perfect fit & interface with other building components Composite wall comprises: - 1.6mm Corten Steel profiled outer sheet plasterboard - 40mm insulation outersheet - lining support rails insulation plywood - 9mm plywood primary lining - 2 layers of plasterboard secondary lining rails standard shipping “castings” - used for lifting docking & securing Composite floor comprises: - 28mm plywood - 100mm mineral wool insulation - rubber separation gaskets - “C” channel steel joists - 1.6mm Corten steel flat outer sheet
- 19. VERBUS TECHNOLOGY Geometries Verbus Module dimensions can be a range of sizes. The most common dimensions of which are 6ft or 8ft x 40ft (2,438mm or 3660 mm x 12,192mm). The adjacent Matrix highlights how Verbus Modules which harmonize with multiples of these dimensions to give greater economies. Longer units combining more volumes into a single module will provide greater savings than a series of smaller modules containing the same independent spaces. Projects are not limited to 'standard' sizes and a full range of Module sizes can be provided. Geometry ‘V’ Economy Matrix: minimum optimum maximum 6058 to 12192 to 14273 minimum 2438 variable widths to optimum 3660 to Good Value Very Good Value maximum 4022 Excellent Value variable lengths
- 20. VERBUS TECHNOLOGY Structure stability side & end unit walls to provide Verbus Modules are high strength building stability steel frame and metal plate diaphragm structures based on universal shipping container design, revised to suit the requirements and demands of the construction industry. The units are fabricated from rolled steel sections, with the wall structure of the shipping container acting as a load bearing structural element and floor and roof construction designed to satisfy the loading and dynamic response conditions of a multi- storey building. Because of their inherent strength, the units can be stacked as high as high as 15 to 20 storeys. For stability, the units laid side by side are connected to each other using spigots and sockets, and bolted plates. When fully connected the units are mostly self load paths stabilising and do not require the support of corner + intermediate posts support vertical loads independent steel frames or cores.
- 21. VERBUS TECHNOLOGY Assembly and H&S Assembly is simple, fast and safe. The Verbus System can be provided on a simple foundation solution or on a steel or concrete podium. The design allows for rapid erection with low-technology, fail safe bolted connections. The units are weatherproof so that interiors remain protected during the assembly process. Modules are fully fitted out before arrival on site. Modules can be erected and bolted together internally without external scaffolding. The installation process includes a temporary barrier system which in conjunction with man-safes and safety harnesses provides a rapid and safe method of construction. Due to the small number of large lifts and the absence of traditional materials on site, this modular construction method offers the opportunity for a significant reduction in the number of hazards on site.
- 22. VERBUS TECHNOLOGY Robustness & Durability boxes high yield structural steel boxes bolting phase 1 The Verbus units are manufactured internal corridor bolting from weather-resistant Corten A steel. This is a material with a yield stress of at least 375N/mm2. The Corten A steel is used for the corrugated walls of the unit and also for rolled steel sections including perimeter beams and load bearing posts. When bolted together, the boxes form a continuous tied structure which prevents disproportionate collapse of the building should a single unit become damaged and fail. The external steel box also provides a vapour barrier, and allows the individual building elements to be weather- tight during transportation and construction The units have been prototyped and load tested, and all materials are certified by testing. corrosion protection Workmanship in the factory is painted corten steel (anti-rust) protection bolting phase 2 independently monitored and controlled by external vertical and horizontal bolting ties to prevent Lloyds Insurance. disproportionate collapse
- 23. VERBUS TECHNOLOGY Fire Strategy fire protected riser shaft cavity between units: class 0 fire sterile environment The building system is designed fire resistance of unit is 1 - 2 hours to meet Building Regulations for Fire Safety, which covers means of escape, spread of flame, fire performance and access for fire- fighting. The modular units can be built to resist a fire for up to 2 hours. Spread of flame through the corridors or via the windows is prevented by conventional fire stopping. The spaces between the units are treated as fire sterile areas and are sealed off from the other spaces in the building. In the event that a module is damaged during a fire the surrounding units remain tied together and fully supported. Escape stairs and corridors can be treated in a similar way to a conventional building. corridor “zip-up” linings provide cavity fire barriers external envelope insulation provides fire barrier in cladding zone
- 24. VERBUS TECHNOLOGY Acoustic Performance >54 Dntw Ctr dB Floor/ceiling noise reduction The modular units meet and floor to ceiling impact noise transfer < 55Lntw dB exceed minimum building regulation noise reduction levels, and can accommodate sound isolation requirements for residential and hotel buildings. Air borne noise and structure borne sounds are successfully isolated by the layers of plasterboard, insulation and air gaps between the units. A range of external noise isolation measures can be achieved through the specification of appropriate cladding working in conjunction with the noise reduction of the units themselves. >50Dntw + Ctr dB noise reduction between rooms units + external cladding provide noise reduction
- 25. VERBUS TECHNOLOGY Thermal Performance it should be noted that the outer steel sheet of the Verbus unit is The Building Regulations will considered as the vapour barrier. In order specify minimum standards to be achieved for this to be successful, and to mitigate the risk of interstitial condensation, for thermal performance of the building additional insulation must be provided against the external steel face of the unit. design, including the building fabric. The assessment method usually requires the performance of the entire building to be composite roof: R=1.31m2K/W measured against standard criteria for carbon emissions. The thermal performance of the Verbus System is measured in conjunction with the external wall and insulation, plywood and minimum 2 layers composite wall: R=1.09m2K/W plasterboard for combined optimum thermal and acoustic performance, composite floor: R=1.31m2K/W achieving the best possible elemental value without compromising the available floor area. The adjacent diagram provides indicative elemental Thermal Resistance Values (R - Value) for the wall, floor and roof of the Verbus Systems Shell. These values can of course be increased, with a small loss of floor area, by increasing insulation thickness and lining specification.
- 26. VERBUS TECHNOLOGY Heat & Ventilation extract via bathroom riser heat & ventilation option 2: supply & extract temperature controlled air ducted from roof to fan coil units in bedroom ceilings The units can meet current Building Regulations standards for thermal performance, air-tightness and general building servicing requirements with an appropriate specification for the building fabric. Heat and ventilation can be provided locally in the modules or if a sealed façade and ducted air solution is required, via temperature controlled ventilation fancoil units. The modules are pre-fabricated with pre-formed service riser positions to allow the installation of ductwork both horizontally and vertically. Plant and equipment outside the modules will be installed on site, with the pre-fabrication concentrated within the heat & ventilation option 1: modules and local risers. external trickle ventilation The level of pre-fabrication local heater unit in the room will vary between the different types of building and there will be connections of ductwork and services to be made between the units horizontally and vertically dependant on the design strategy for the ventilation system of the modules.
- 27. VERBUS TECHNOLOGY Sustainability 40 year life cycle Material Transport Dismantling Extraction Second to Construction Operation & rebuild/ and operation site Rebuild processing The Verbus building system brings the following benefits in terms of Stage 1 Stage 2 sustainability: 1. Minimised transport and CO2 Stage One & Stage Two: Impact of Reuse Summary of Verbus Building emissions. (over 40 year Design Life) Materials are sourced close to the factory. The steel used contains re-cycled material. The amount of fossil fuels used for shipping and transportation is less than the fuels used for deliveries by traditional on-site construction techniques. 2. Re-use of the units. The units can be unbolted and refurbished for re-use. They are also flexible and adaptable for modification. 3. Minimised use of Materials and Waste. The prefabrication process maximises the use of material in manufacture, and minimises waste created on site. 4. Good Air-tightness and thermal performance. The continuous outer steel box prevents air leakage allowing venting to be carefully controlled through trickle vents. The Alternative technologies can be incorporated into the Verbus box is insulated inside and out providing good thermal and system to reduce external power and water consumption, such as: acoustic performance. 5. Shading devices and other façade Solar thermal collectors, Photo-voltaics, Ground source Heat pumps, Biomass boiler, Greywater elements: These can be modularised and fixed to the Recycling. outside of the Verbus boxes without additional strengthening. The other measures that can be taken to reduce the environmental impact of the building include good building orientation and use of daylight, natural ventilation and cooling, efficient land use, respect to ecology, efficient water usage, good operation management, and low energy services such as lighting.
- 28. VERBUS TECHNOLOGY Standard Details wall construction (plan) roof construction (section) floor construction (section)
- 29. 5 Verbus FAQ’s > Structure > Manufacture & Delivery > External Treatment: Roofing Facade/ Cladding > Glazing > Acoustic Design > Conservation of Fuel & Power - Thermal > Fire Safety > Drainage > Mechanical & Electrical > Internal FF&E > Resistance to Contaminants & Moisture > Toxic Substances > Stairs Lifts & Protection from Falling > Certification & Design Life
- 30. Verbus FAQ STRUCTURE 1. What is the wall make-up between units for wall acting as party wall? Standard Verbus detail would be two layers 12.5mm fireline, 1 layer of 10mm plywood, 40mm metal stud with rockwool insulation 1.6mm Corten steel folded to give a 20.5mm corrugation. There would be an air gap of approximately 28m before adjacent unit provides an identical wall build up. Typical overall thickness 220mm. 2. What is the wall make-up for an external wall? As detailed above, but Corten steel wall would then have additional insulation, a cavity then the external facade (brick, rendered panel , timber, aluminium cladding etc.) 3. There appear to be a number of posts in the front elevation: is this standard or is this due to opening that is created? There are some posts required in the end walls to give the unit robustness during shipping and stacking on a vessel. Some of these posts can be removed once the unit is in its permanent state (i.e. erected as a building). Some Posts are to form window/ door apertures as required. 4. Is it possible to completely remove the front of a unit? Dependant on width of unit and adjacent structure. The top, bottom & end joists will always be required as will the columns on the corners of the unit. The remainder of the end wall could be removed in the right situation. 5. Will our openings require similar framing? Yes. All openings will need to be framed. There is an opportunity to use the essential elements of structure for this framing (as mentioned above) or an additional frame would be required.
- 31. Verbus FAQ STRUCTURE 6. Do Verbus design and warrant the overall building stability including core? Verbus will warrant the design of the structure of the Verbus elements of a building. Where a building contains elements of steel / concrete frame (i.e. cores or large open span areas) these elements may designed by the Verbus project engineer. It is the project engineer who takes overall responsibility for the building as a whole. 7. Do Verbus provide wind loading design? Verbus units will be designed for wind loading pressures provided by the structural engineer. 8. Do Verbus provide load bearing design including cladding loads? Dead and live loads would be agreed with the structural engineer. Verbus can provide loadings for interface with supporting structures (e.g. Transfer decks and cores.) 9. Do Verbus provide disproportionate collapse safeguard design? The units are designed and detailed to transmit tie forces to BS 5950 in the event of loss of support. 10. Do Verbus provide loadings for ground slab design? Loads due to Verbus units in contact with the ground slab would be provided by Verbus to the structural engineer designing the ground floor slab. 11. Do Verbus provide loadings for design of foundations? Verbus provides unit loads for incorporation into foundation designs. Note that weight of cladding, roof top plant and other loadings to be provided by the structural engineer.
- 32. Verbus FAQ MANUFACTURE & DELIVERY 1. What would be the period required for Verbus to prepare drawings, issue for comment, amend and re-issue for construction? Very much dependent on the size of project and variation of unit types. Typically 6-8 weeks from order being placed to Verbus Design Freeze being achieved assuming the Clients Design is “frozen”. 2. What period would be required for manufacture and despatch from factory from the date of construction issued drawings? Typically twelve weeks. 3. What period would be required from factory despatch date for shipping and delivery to site, including time to negotiate exit and entry ports? Typically four weeks. 4. What holding/ storage or other arrangement is provided by Verbus to facilitate a phased delivery to meet the site programme of erection? As required we use a national road haulier with storage facilities throughout the UK 5. Given a clear run, what average site erection rate would Verbus expect to achieve per week – (modules delivered, placed and structurally connected.) Verbus could achieve a rate of ten units per day 6. Will Verbus inspect / accept foundations and erect modules, and attach structurally to the cores and foundations. This is subject to contract conditions. Verbus can carry out these procedures if required
- 33. Verbus FAQ MANUFACTURE & DELIVERY 7. What protection do units have in transit? The outer skin of the units is 1.6mm Corten Steel. This requires no additional protection. 8. What happens if the boat sinks or a unit falls off the side of the vessel? Verbus provide insurance to cover any such transit related issues. This insurance is valid from the manufacturing facility through to delivery to site.
- 34. Verbus FAQ EXTERNAL TREATMENT: ROOFING FACADE/ CLADDING 1. Have you ever used a bespoke metal cladding solution externally? There are currently two live projects which utilise metal cladding in part of the external façade system. However the outer face of the unit must be insulated. 2. What rules have to be followed for the fixings / spacing of cleats etc. which cladding rails, trims and flashings can be fixed to? The Verbus units provide fixing points for cladding rails at the top and bottom of the side and end walls. Should brick ties or similar be required then plates are welded to the external skin as required. 3. Cladding connection provision The Verbus units have a steel structure allowing different cladding systems to be fixed to the outside of the units. Flat plates, “Ancon” brackets and other fixing points are provided on the unit for cladding attachments to be added. 4. What types of cladding can be applied to the module and what provision do Verbus make in each case for fixing. Any cladding system can be fixed to a Verbus unit. The standard provision is either brick tie plates welded to the external skin of the unit plus “Ancon” brackets along top and bottom rails to take vertical cladding rails. We would have early discussions with the cladding contractor to ensure that the interfaces are known. 5. Do Verbus normally provide external doorsets and/ or windows factory fitted and glazed? No, not normally. If the employer requires such items they can be supplied loose inside modules. However windows & doors could be pre-installed in the right situation. 6. Can a parapet detail be added to the Verbus units by means of a standard Verbus connection detail? Previous projects have had parapets formed in situ from a timber construction fixed through into the top rail of the units. However in the right situation yes this could be achieved.
- 35. Verbus FAQ GLAZING 1. How do you deal with window penetrations in a UK brick clad scheme? With particular interest in what the sequence / detail is once the opening has been 'knocked out'. Is the reveal of the Verbus unit simply dry lined from within on site? The window reveal has straps or brackets fixed to it to support the window (which is primarily in the wall cavity). Once the window is fitted the reveal is lined with 1 layer 12.5mm vapour check plasterboard and 1 layer 12.5mm soundbloc plasterboard as standard 2. If the reveal is dry lined on site, how is fixing achieved into the steel surround? Are grounds required first? Grounds are not required first. The plasterboard can be fixed directly to the steel frame of the window aperture. Alternatively a plywood lined reveal could be provided. 3. Is the window normally fixed into the Verbus unit rather than the outer cladding system? This would replace the need for a lined reveal with a simple finish like an architrave. Both are possible. The client usually prefers to have an internal cill detail as a more traditional construction would provide, therefore the window is fitted in the cavity between Verbus wall and external façade. However if there is no requirement for an internal cill or reveal the window can be pre-installed in the unit providing it does not protrude beyond the face of the outer sheet.
- 36. Verbus FAQ ACOUSTIC DESIGN 1. What sound insulation value does the unit have without additional insulation? Results of theoretical predictions and model constructions For single external wall: Assumptions: Plasterboard 2 layers of 12.5mm board with mass 17.3kg/m2 Plywood 1 layer of 10mm plywood with mass 5.6kg/m2 Void 50mm with 40mm of mineral wool Steel 1.6mm flat steel 12.5kg/m2 Sound reduction index Rw - 51 2. Vibration: To meet design code and Employer's requirements. <= 55Lntw dB 3. Acoustic Design: To meet both Employer's requirements and Building Regulations – impact and airborne sound walls and floors. The design of a standard Verbus unit is such that previous test data confirms it easily attains those targets set by Building Regulations. Acoustic performance measured as a combination of Verbus build-up and external walls. Room to room acoustic performance measured on previous Verbus buildings. Room to room noise reduction: >= 50Dntw +Ctr dB Floor to ceiling noise reduction: >= 54Dntw +Ctr dB
- 37. Verbus FAQ CONSERVATION OF FUEL & POWER - THERMAL 1. What U value does the unit provide without additional insulation? The unit has the following thermal resistance, which when combined with external cladding and insulation provides a U- value: - wall: R=1.09 m2K/W - roof: R=1.31 m2K/W - floor: R=1.05 m2K/W 2. Does the external insulation need to be positioned tight against the outer face of the unit? Can an air gap be provided with a composite, Kingspan type, insulation or does this cause problems with interstitial condensation? No requirement to place insulation against outer face of unit. 3. Air Tightness Design: To meet both Employer's requirements and Building Regulations including interstitial condensation calculation check. Part L calculations normally carried out by project building services engineer or architect. Construction details of the Verbus units provided by Verbus. 4. Thermal Design: To meet both Employer's requirements and Building Regulations including interstitial condensation calculation check. The thermal properties of the Verbus units are such that additional insulation is required outside of the units in the cavity behind the external cladding / façade. Part L calculations normally carried out by project building services engineer.
- 38. Verbus FAQ FIRE SAFETY 1. What is the Fire rating for a Verbus Unit and what level of protection is given to its structural elements? 90 minutes standard. Verbus units are fire rated as specified by the architect. Up to 2 hours protection possible.
- 39. Verbus FAQ DRAINAGE 1. Services Design: Provision of service risers as shown, to meet needs of M&E and Building Regulations Apertures in floor and roof of Verbus units are provided to give vertical access through the building for services. Sizes of these apertures vary dependant on services required and height of building. Risers are generally sized by M&E consultant.
- 40. Verbus FAQ MECHANICAL & ELECTRICAL 1. Are power and data services run within the wall cavity? Yes. Where certain specialist cabling cannot be supplied (i.e. data or fire) then containment is provided within wall construction with draw wires. 2. What electrics would be included and how would they interface with distribution mains – plug and play or traditional connections? Units will have first fix electrics with regard cabling and containment. Where cabling cannot be supplied (i.e. fire) conduit will be provided with draw wires. 3. How is electrical / mechanical certification achieved? M&E services are tested and certification provided at the point of manufacture, under the supervision of an independent representative.
- 41. Verbus FAQ INTERNAL FF&E 1. For surface mounted items, such as shelves, are additional studs added to the wall construction or is the plywood sufficient? Typically the standard 10mm plywood behind the plasterboard provides sufficient grounds to fix into. Should a more substantial substrate be required this plywood can be increased. 2. Will Verbus fit out internally to a specification to meet the Employer's Requirements or a pre-determined specification used previously that may not align with Employer's specification? Each project is treated on its own merit, however Verbus. units will be fitted out to the employer's requirements as detailed in the terms of contract unless otherwise agreed. 3. Which components would be sourced from UK? Those which cannot be sourced in China. Typically these are reasonably few but can include specific data cabling or fire detection systems. 4. Which components would be sourced from Europe? Only those which cannot be sourced in China or UK. 5. Which components would be sourced from China? The majority of the components will be sourced in China as quite often the specified components are made in China. These can include sanitary ware, doors and door furniture, beds, light fittings etc. 6. Would bathrooms be 'podded'? Would connections be to UK standard? Verbus have provided both bathroom pods and built-in bathrooms. It has proved more productive to construct the bathrooms in the units in the factory rather than use pods. All connections will be to UK standard.
- 42. Verbus FAQ INTERNAL FF&E 7. What happens any of the goods supplied are defective? Verbus ensures that replacement products are available in the country of the site and will arrange for replacement to be made where appropriate
- 43. Verbus FAQ RESISTANCE TO CONTAMINANTS & MOISTURE 1. How are DPCs dealt with where they are required at opening positions? As with traditional construction a Thermabate or similar would be incorporated into the external wall construction around the openings.
- 44. Verbus FAQ TOXIC SUBSTANCES 1. Does the standard Verbus wall insulation contain Urea-formaldehyde foam of any other substance which could be hazardous to health? If so, how is this managed? No. The insulation in the Verbus wall is an approved Rockwool product.
- 45. Verbus FAQ STAIRS LIFTS & PROTECTION FROM FALLING 1. Do Verbus have a solution for a staircase within a Unit? A staircase solution, although not offered yet, is in design stage. 2. Design of interface connection of modules with stair/lift shaft cores etc. Verbus provides loads and recommended connection details between the units and stair/lift cores
- 46. Verbus FAQ CERTIFICATION & DESIGN LIFE 1. Longevity 60 year design life. 2. Do the Verbus units carry any recognised certification? (Eg BBA; BRE; Warrington Fire; ETA; BS or ISO compliance.) Designed to meet UK standards, BS codes etc.