Intrastack's pre-manufactured steel frame system was specified for a six-storey apartment complex, Abbey Wall in Merton, Southwest London. The result was a development constructed 15 weeks faster than traditional concrete methods, while the offsite fabrication also reduced health and safety risks and cut waste by 50%. This project demonstrated the effectiveness of Intrastack's system in delivering a durable, high-performance solution that balances speed, safety and cost.
The Abbey Wall development project showcases the potential of offsite construction and the use of steel frame systems when implemented in main building structure. This six-storey mixed-use residential scheme, comprising 66 apartments and a commercial unit on the ground floor, was completed 15 weeks faster than traditional concrete construction methods while reducing costs and on-site safety risks (calculated based on a standard 30-week programme plus 10 weeks of exterior wall construction for a concrete frame, versus 25 weeks for a complete steel frame structure).
The project utilised an offsite manufacturing process, with steel frames fabricated in a controlled environment that ensured quality, precision and process-driven production. Intrastack's pre-manufactured steel frame system was chosen for its strength, weight-bearing capacity and the ability to expedite the construction process. The lightweight nature of the steel frame system allowed for a versatile structure that supported the composite concrete floors while significantly reducing foundation loads and sizes by over 70% relative to concrete and blockwork construction (figures provided by the Steel Construction Institute – Technical Information Sheet ED020). The coordination of delivery sequences and the installation process allowed for a seamless transition between offsite fabrication and on-site assembly. This approach not only shortened the construction timeline but also mitigated potential safety hazards associated with on-site fabrication.
By implementing Intrastack's steel frame system, the project achieved significant cost savings, estimated to be around £60,000 in labour and plant costs. Offsite manufacturing techniques helped control waste production, leading to an estimated 50% reduction in waste and promoting responsible disposal or reuse of offcuts. The steel frame system's thermal insulation and airtightness contributed to energy efficiency, further reducing the building's carbon footprint. The combination of steel frame construction with a concrete floor enhanced the building's acoustic performance and provided 120-minutes of tested fire protection. The resulting structure boasts durability, high performance and the ability to stand the test of time with an average lifespan of up to 250 years for a steel-framed building with warm wall construction, as predicted by the Steel Construction Institute (Technical Information Sheet ED022).
Intrastack’s Technical Product Manager Matthew Grant, adds "From the initial concept drawings, we have worked with RJB and Indigo Scott to construct a durable, high-performance steel frame system that would meet their needs for speed of construction, improved on-site safety and a reduction in build cost.”
Due to utilising light steel framing and offsite methods of construction, the Abbey Wall development project was completed 15 weeks faster than traditional concrete methods, had a reduced carbon footprint resulting from high levels of thermal insulation and airtightness, boasted cost savings, as well as visual appeal. The steel frame system allowed for versatile and lightweight structural design, providing a visually appealing and modern aesthetic. The precision achieved through offsite manufacturing resulted in an accurate and high-quality finished structure that is both functional and visually striking.
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