Dace Road mixed-use development in Hackney Wick, London

Dace Road is a 6,500m² mixed-use development which sits in a prominent location, at the entrance to Fish Island, close to the London Olympic Stadium in Stratford. The area of East London is currently undergoing major regeneration. Existing warehouse structures were demolished to make way for 5 blocks comprising 144 residential units and a commercial unit – all with new public spaces and complete with a commercial courtyard.

HG Construction worked together closely with MAX FRANK to overcome initial construction challenges, and through a series of technical workshops, value engineered the product to work within the development’s build.

Thermal bridges can create increased thermal losses and can be caused by material properties and geometry. The impact of thermal bridging often results in heat loss, condensation and ultimately mould formation within the building. Thermal bridging can be combatted through the control of such factors, using credible thermal break solutions.

Egcobox^® thermally insulated balcony connectors, create a thermal break between an external component and an internal component.

The structural function of the Egcobox^® unit is provided by a reinforcement framework, manufactured from reinforcing steel, which passes through the thermal insulation and thus connects the unit to the building.

Depending on the choice and alignment of the bars, bending moments and shear force can be transferred. The thermal performance is determined by the insulation material between the internal slab and the external concrete member. For fire protection reasons, mineral wool insulation with low thermal conductivity is regularly used.

The most common application for MAX FRANK Egcobox^® is to minimise thermal bridging between the slab and balcony. However, in this case, Egcobox^® thermal break units were also supplied to prevent thermal bridging between external insitu cladding panels and the internal concrete structure – designed for both horizontal and vertical cladding panels.

Thermal breaks combine structural safety and ideal heat insulation. Egcobox^® units are usually installed as cantilever connectors in balconies and in parapet walls. The structural stability of Egcobox^® is provided by a framework of steel reinforcement passing through the 60 to 120mm thick mineral wool/rockwool insulation to guarantee fire protection to REI 120. Egcobox^® reliably connects components, such as balconies, to the building and encloses roof decks through the installation of parapet walls. The placement of Egcobox^® thermal break connectors, in balcony application on this project, is highlighted below.

The precast stone banding allowed the project contractors to achieve good quality control on the finish of the stone banding to achieve uniform tonal consistency and a distinctive finish. It also provided assurance when planning and programming, knowing that the banding was cast and ready for installation as the frame was erected during construction. As a structural element, the banding also acted as the masonry support for the façade at each storey level. This is where MAX FRANK Egcobox^® came in.

Images ©BuckleyGrayYeoman

Bespoke Egcobox^® units were designed and fitted within the insitu façade panels. Egcobox^® types FXL & MXL, to REI 120, were specified and designed for this project:

The installation process involved casting the specially manufactured Egcobox^® unit into the floor slab. The thermally insulating cantilever connection system, to REI 120, forms a thermal break between the cladding panels and the insitu concrete structure, transferring load whilst maintaining the building’s full structural integrity (see the below illustration).

The below images show the precast stone banding panels in place on Block C and a close-up demonstrating the accentuated fluted detail achieved at each balcony.

The versatile and adaptable Egcobox^® thermal break connection system provides fire protection to REI 120 and conforms to the amended Building Regulations 7(2) for combustible products for England. The thermal break units, also available for curved and steel-to-steel applications, were specially designed by MAX FRANK’s technical department and custom-manufactured for this specific project – and its varying applications. The Egcobox^® software allowed straight-forward modelling of thermal break application. By analysing the forces acting at the connection, the software suggested appropriate units that could transfer the moment and shear forces safely from the external balcony to the internal slab side. Egcobox^® was so successful in this application on both Fish Island Village and Dace Road, it has since been specified and designed for a similar application on a third scheme by HG Construction, which also forms part of this complete development.