Base delivers revolutionary structure for Nottingham University Samworth Academy
“When it came to developing the design, I appreciated Base’s honesty and straightforward approach. Their wealth of experience in tensile structures was a great advantage, not to mention the quality product which Base installed quickly and efficiently. I would have no hesitation in recommending them.”
Paul Gott, Architect, Atkins
The team
Mark Smith, Head of Projects, Base Structures
Russell George, Project Manager, Base Structures
Nick Croker, Site Supervisor, Base Structures
Paul Gott, Architect, Atkins Global
Project highlights
• Solution – a single ETFE skin using TEXO® a revolutionary framing concept, new to the UK and never before applied in a roofing context
• Almost 40% cheaper than glass and less than 1/10 the weight of glass –including frames
• Virtually indistinguishable from conventional glazing (97% translucency)
• 30 year lifespan
• Faster and safer installation process compared to glass
The background
As part of the Government’s initiative to roll out academies across the UK, Nottingham University and Leicestershire businessman David Samworth co-sponsored the building of a brand new secondary school in Nottingham – the Nottingham University Samworth Academy or NUSA.
The brief
One element of the architect’s design for the academy featured a cable supported, single skin clear ETFE roof over an unheated internal street. The roof’s main function, as well as providing a shelter, was to allow a high level of natural light to enter the street as it was going to be bordered by classrooms. The main contractor, Carillion plc, approached Base for its technical expertise to develop a solution that could deliver all the key functional and aesthetic effects in the architect’s proposal.
The solution
Base won the project on technical experience, by proposing a more robust single skin ETFE solution. By adapting the revolutionary TEXO® cladding system, designed by Tensoforma of Italy, Base proposed to deliver an innovative tensile fabric solution that would offer the required high light translucency (97%), while offering a 30-year design, life thanks to a more modular approach. Initially conceived as a vertical cladding panel, this was the first time that TEXO® had been adapted as an alternative to a glazed solution by using single skin ETFE foil.
The solution also offered a high degree of prefabrication and featured low weight components, which greatly reduced the risk of damage and injury on site. Base undertook the complete design, manufacture and installation process, including the structural aluminium gutters and primary steel arches.
Base solution at a glance
• TEXO® roof comprising a single layer of ETFE foil mounted on a 60m x 60mm extruded aluminium frame
• The bulk of the panels were 200 micron thick, clear ETFE
• 250 micron foil panels were installed near the end of roof to handle increased wind suction forces
• A silicone elastomeric strip ensures foil is held under constant tension, even under varying wind loads
• All frames assembled in a controlled factory environment off-site and delivered as complete and finished units
Fast installation
Each 8m x 1.2m panel weighed just 45Kg which meant it could be easily lifted by two men, avoiding the need for expensive lifting gear, which would’ve been imperative for a toughened glass structure. The installation itself went like clockwork. The 96 panels were packed 24no to a crate and lifted onto the adjoining roof, where two Base engineers handballed the panels into position with the help of operatives working under the roof from MEWPs (cherry pickers). The panels were then carefully moved up the gutter sections on temporary castors. This procedure ensured a speedy installation, taking 4 operatives just 1 day to install up to 75m2.
The results
Base delivered a highly innovative solution that matched the aesthetic requirements with a robust build quality, offering a 30-year lifespan – all installed swiftly and cost-effectively, meeting the brief and budget. The architect was particularly delighted with the high light levels our solution achieved. The NUSA opened to its first pupils on Friday 4th September 2009, and the new building was officially opened by Dame Kelly Holmes DBE in September 2010.
