BLOG | Rapid Evolution of Modern Masonry Techniques Improves Building Sustainability

A building product’s environmental credentials do not necessarily stand and fall on the amount of carbon it emits during use or in situ. Some solutions, such as brick slip lintels, and brick on soffit systems have evolved to speed up and simplify traditional construction techniques, an outcome that delivers significant sustainable benefits by reducing onsite labour times and cost. Kyle Alexander, Project and Engineering Manager at IG Masonry Support, highlights the additional ways in which its high-performance masonry support range helps projects meet environmental targets whilst facilitating evermore imaginative, attractive building designs.

Masonry is a classic and timeless building material that achieves superior, maintenance-free results. Utilising masonry in prominent areas can be essential to delivering an architect’s overall vision, or fulfilling a client’s brief to ensure a project remains in keeping with the local surroundings. Thanks to the evolution of brick slip lintel systems, for example, such design intentions can be achieved more effectively, rapidly and sustainably than ever before.

Time and energy saver

Brick slip systems are adaptable to suit any masonry-based application. They are particularly ideal for small openings over window heads and delivering effortless results spanning an entrance of a commercial building.

Creating intricate masonry details with prefabricated brick-slip solutions such as those supplied by IG Masonry Support results in an estimated 90%-time reduction in comparison to traditional on-site methods. As well as the time-saving factor, there are many other benefits associated with a brick slip system’s offsite production, from improved construction efficiencies and reduced on-site waste, through to minimal site impacts due to the fit-and-forget design.

Environmentally conscious approach

According to the Climate Change Council, the built environment contributes around 38% of the UK’s total carbon footprint. The construction industry needs to reduce emissions by 60% by 2030 and a further 10% by 2040 to meet the government’s Net Zero target. Hence, the building sector is taking an increasingly conscious approach when it comes to supplier and material selection.

Reliable and compliant with building regulations, IG Masonry Support’s brick on soffit system B.O.S.S A1 provides a perfect illustration of how sustainability and performance synergise in high-quality products. The prefabricated B.O.S.S A1 is supported by carbon neutral classification, which along with its A1 fire-rated finish, provides an ideal complement to its ability to create safe, spectacular brick soffits through fast, efficient installation. The unit’s lightweight composition is key to its easy handling; its composite material manufacture makes it 70% lighter than equivalent concrete units. This eliminates the need for mechanical lifting, thus a useful aid to ensuring building projects meet environmental targets.

Case study: The Canal Turn, Nottingham

The Island Quarter, a £650m mixed-use development in Nottingham, offers an ideal example of how the prefabricated nature of brick-on-soffit units is crucial to achieving complex design configurations safely, effectively, and sustainably. IG Masonry Support was selected to design and manufacture 19 Brick Slip Arches for the Canal Turn, the first of three building phases to be delivered for the Island Quarter project.

The greatest challenge in respect of the arches’ delivery was coordinating the brickwork design of two deep-soffit arches, which were required to meet at a 90-degree angle at the structure’s ground-level corner. To achieve this, a half-arch solution combined with a B.O.S.S A1 deep-soffit system, facilitated the return of brickwork on the arches’ soffit whilst completing obscuring unsightly steelwork. The prefabricated B.O.S.S A1 system ensured the Canal Turn corner arches were an identical fit, resulting in a finish that earned a praiseworthy testimonial from installing contractor Gareth Williamson, former Project Manager at Lee Marley Brickwork.

Speaking of the project, Lee said: “IG Masonry Support’s method of using stainless steel in the arches proved ideal in getting them to site and installed using safe working methods. The B.O.S.S A1 deep soffit units are so much lighter than other products on the market, making it a lot easier for the arches to be lifted into position. The arches look great and when the Canal Turn building’s lit up, it looks amazing.”

As the Island Quarter development demonstrates, the evolution of masonry support elements such as brick slip lintels and brick on soffit systems have become essential to expanding the use of one of the world’s oldest, most reliable building materials in evermore exciting – and less impactful – ways.

NEWS | Keystone Group launch ‘Future First’ Sustainability Strategy

The Keystone Group is delighted to launch its sustainability strategy, Future First, outlining how it is building decarbonisation into all business operations on its path to becoming one of the first UK manufacturers in the construction sector to achieve carbon net zero. 

Founded on the pillars of Our Planet, Our Products and Our People, Future First represents Keystone’s passion and commitment to driving sustainability in every aspect of its business to help create a better future for everyone. Under the Science Based Targets Initiative, a global organisation responsible for setting the world’s targets to ensure a more sustainable future, Keystone has embarked on a journey of monitoring and improving its carbon emissions and has committed to the ambitious target of becoming Net Zero by 2050.

Each brand within the Keystone Group has set targets to reduce their operational impact as well as source responsible materials, whilst continuing to deliver  innovative solutions at minimal expense.

Sean Coyle, Keystone Group Chairman said: “Our journey to becoming a sustainable business is a critical objective for all Keystone Group brands as we progress towards 2030 and beyond. We all have a key role to play in achieving this objective.”

Jemma Ison, Group Sustainability Manager said: “With the built environment and construction sectors accounting for around 38% of global carbon emissions, the journey to becoming a sustainable manufacturing business holds greater significance than ever before. We are delighted to be launching our Future First sustainability strategy, which demonstrates the steps we are taking on our route to net zero.  This is essential for our customers and for the future of the built environment.”

Keystone recognises the importance, as well as the urgency, to focus on protecting our environment by improving its business operations. At a critical juncture for our planet, Keystone is playing a part in this global challenge by operating responsibly and putting our future first.

To find out more about the Keystone Group’s Sustainability Strategy visit www.keystonefuturefirst.co.uk.

BLOG | Prefabricated masonry techniques elevate brick’s status as a sustainable building material

Brick is one of the world’s most sustainable building materials. Reliable, durable, and recyclable, bricks’ evolution as a low-impact product has been hastened by the introduction of increasingly innovative masonry support systems. As Jemma Ison (Keystone Group Sustainability Manager and IG Masonry Support Specification Executive) highlights, these prefabricated techniques have not only expanded the architect’s palette in terms of brickwork design, they have advanced and simplified the build process to give bricks a sustainable advantage over other established materials.

Masonry is a classic and timeless building material that achieves superior, maintenance-free results. Utilising masonry in prominent areas can be essential to delivering an architect’s overall vision, or fulfilling a client’s brief to ensure a project remains in keeping with the local surroundings. Brick Slip Systems are adaptable to suit any application. Ideal for small openings over window heads but also deliver effortless results spanning an entrance of a commercial building. Whatever the desired finish, IG Masonry Support‘s prefabricated units provide high-quality results at low environmental impact.

Time and energy saver

The average time it takes to create intricate masonry details with prefabricated brick slip solutions is estimated to reduce time by 90% in comparison to traditional onsite methods. As well as the time-saving factor there are many other benefits associated with offsite production, from improved construction efficiencies and reduced onsite waste to minimal site impacts due to the fit-and-forget design. Furthermore, a prefabricated unit is produced in line with manual handling guidelines. Therefore, designed to be easily managed and handled onsite. This eliminates the consumption of any fuel or electricity needed to aid the installation process.

Skills shortage

Whilst highlighting the direct and indirect sustainable benefits of these prefabricated methods, it is also a recognised challenge that traditional techniques require the services of a highly-skilled bricklayer. In the current climate, this might not be an appointment that is easy to secure. The bricklaying sector, as with the construction industry as a whole, is in the midst of a well-publicised skills shortage. Indeed, the Construction Skills Network (CSN) has forecast a need for 1,450 more bricklayers per year over the next five years to help fulfil UK building projects. Therefore, it could mean an appropriately-qualified bricklayer travelling many miles to work on a particular project, a journey that would incur additional fuel consumption and environmental impacts.

Natural hindrances to efficient brick detailing 

When it comes to achieving intricate brick details, a building site is far from the ideal environment. Poor weather can hamper high-quality workmanship and build consistency. This can lead to reworks and additional project time, cost, and material waste. Whereas offsite manufacture takes place in a controlled environment, enabling products such as brick slip systems to be produced with greater skill and accuracy.

Safe and adaptable solution  

Due to their A1 fire-rated finish, IG Masonry Support’s prefabricated brick slip products provide peace of mind to specifiers due to their reliability and compliance with building regulations. The product range includes the company’s ultra-lightweight brick on soffit system, B.O.S.S A1. A component building part, the product’s superb performance is supplemented by its sustainable credentials, which are supported by its carbon neutral classification. In addition, IG Masonry Support’s Brick Slip Arches have increased design options for architects looking to use masonry in evermore striking and imaginative ways. Manufactured offsite, the Brick Slip Arches are bespoke designed to order, and delivered to site replete with brick slips adhesively bonded to a stainless-steel unit. These lightweight units facilitate fast and efficient installation and integrate seamlessly with brickwork constructed onsite.

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Environmental Product Declarations

IG Masonry Support is committed to becoming a net-zero carbon business in line with the Science Based Targets. Its adoption of Environmental Product Declarations (EPD) is further evidence of its sustainable ambition. The company is the UK’s first masonry support supplier to issue EPDs on its products, thus providing full transparency of their environmental impact. The declarations are in accordance with GreenBook Live EPD system.

A Type III environmental label, an EPD is generated using data obtained through Life Cycle Assessment (LCA). This is performed via a peer reviewed Product Category Rules document (PCR) in line with EN 15804 (the European Standard for the generation of EPD for construction products), ISO 14025, and other related international standards.

Dual benefit

In terms of their installation, IG Masonry Support is the only UK manufacturer to offer a solution that has dual security using an A1 fire-rated adhesive as well as a secondary stainless steel mechanical fix, providing safety and added aesthetic consistency.

In short, prefabricated brick slip systems are ideal for wherever an intricate brick detail is required. Their specification and installation are made all the easier and more effective through engagement with a prefabricated brick slip specialist such as IG Masonry Support. The company’s single point of contact controls the design, pricing, and manufacturing process, providing tentative support and expert communication throughout a project.

Quality, consistency, and greater sustainability are the ultimate outcomes of the correct specification of prefabricated brick slip solutions, which are gaining in popularity as developers and architects look to expand the use of one of the world’s oldest, most reliable building materials.

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BLOG | A holistic approach is key to the construction sector fulfilling carbon zero targets

The delivery of sustainable buildings has been a focus for many years, writes Andy Neal, Managing Director of IG Masonry Support, but with the UK government requiring the country to be net zero by 2050, the need for the construction industry to improve its emissions output has become more acute.

Whilst buildings that offer low energy in-use are critical, the environmental impact of materials and their production is just as important. If manufacturers are to fully take ownership of their sustainable responsibilities, it will require making a holistic assessment of their overall environmental impact. This includes focusing on their day-to-day production processes, which will play a large part in delivering low carbon buildings of the future. Therefore, committing to a companywide approach, rather than focusing solely on the environmental credentials of its products, is integral to a successful carbon zero strategy.

Taking the initiative for product innovation

IG Masonry Support’s carbon zero programme was set up because we as a company wanted to be recognised as a sustainable organisation in our own right, regardless of what other businesses were doing. But it also dawned on us that manufacturers such as ourselves had a big responsibility to innovate the low carbon products the construction industry needed to increase the carbon efficiency of the UK’s future building stock.

Providing a wider range of sustainable products will give builders greater influence when it comes to the reducing environmental impacts of the properties they are creating. This is far from the case, currently. It’s estimated that even major housebuilders have only 1% control over the building process, because everything they build with is supplied by a host of different sources which vary in sustainable composition and performance. Therefore, to build with greater efficiency and consistency, construction companies need to engage with responsible sustainable manufacturers, who in-turn need to innovate products that result in less environmental impact.  Improving building sustainability isn’t a standalone exercise. Individual companies have the capability to control the eco-friendly aspect of their business and products. Ultimately, however, it’s the responsibility of the building supply chain to innovate solutions that provide end users with the best possible chance of creating sustainable buildings.

Sustainable steps

The first major steps in our sustainability journey were taken when we switched to 85% recycled stainless steel and reduced our landfill waste to 0% in 2018. We have continued to take leaps towards achieving our ambitions and more recently became a carbon neutral organisation. This was achieved by enlisting the services of an external body (Carbon Footprint) whose initial task was to clarify how far short we were from our target. Following this assessment, we embarked on an offsetting programme to reduce the business’s CO2 emissions. We further reduced our emissions footprint by changing to a ‘green’ utility supplier and swapping our diesel trucks for an electric fleet. Furthermore, our purchase of less energy intensive fibre laser cutting machinery has also reduced our material waste.

The introduction of our carbon neutral programme coincided with the launch of our B.O.S.S A1. an ultra-lightweight brick on soffit system. As a component building part, its carbon neutral status was important to us. Its certification soon led to the company’s carbon neutral classification in June 2021. Achieving this required us to do our homework to fully establish what carbon neutrality actually consisted of, as well as understand the legislation behind it. For this we recruited a Sustainability Manager from within the company. Having a staff member being trained by external bodies to ensure companies within our group were fully-versed in carbon neutral legislation was an important step for us. Our Sustainability Manager now heads-up a team of volunteer staff who meet weekly to discuss ways in which we can progress our net zero ambition.

In terms of our offsetting initiative, rather than simply plant trees, we’ve invested in long-term sustainability energy programmes. Hence, our commitment to wind and solar schemes. Through our acquisition of a gap analysis template, we hope to demonstrate how such schemes are significantly reducing our offsetting requirement less and less each year.

Following the science

Our actions do not stop there, however. We are following Science-Based Targets Methodology, which has achievement parameters of between five and 15 years into the future. This process is being carried out alongside our collaborative workshops with the British Standards Institution, which have helped sculpt a sustainable culture into IG Masonry Support. It’s helped formed an approach to sustainability that focuses on optimising our social, financial and intellectual capital, as well as our environmental wealth. These key elements ensure our strategy is inclusive, reflects our company values and importantly, will be successful. It is our mid-term aim to reduce our Scope 1 and Scope 2 emissions by 76% which covers direct emissions from owned or controlled sources, and indirect emissions from the generation of purchased electricity, steam, heating and cooling consumed by the reporting company, respectively.

I believe we attained carbon neutral status sooner than anticipated because of the company’s inherent desire to do the right thing, rather than wait to have measures forced upon us. Whether it’s achieving ISO 9001 certification or matters related to any form of industry compliance, our approach is always the same. We don’t carry out these processes as a box ticking exercise by rushing to get all the paperwork the day before the auditor comes in. We have a dedicated sustainability team set up who are passionate about driving this forward. We do it properly because we want to advance our business’s carbon zero status, the quality of our product and help facilitate a sustainably-built environment for future generations to enjoy.

Check out IG Masonry Support’s Sustainability Journey>>

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Photo caption: IG Masonry Support achieve Carbon Neutral Status (Left to right) Jemma Ison (Keystone Group Sustainability Manager), Kyle Alexander (Project & Engineering Manager), Andy Sharlot (Chief Designer), Andy Neal (Managing Director), Oliver Ball (Operations Manager) and Stephen Jennings (Financial Controller).