Corus Living Solutions is an offsite manufacturer of volumetric steel framed finished room modules employing the following technologies:

·         Modern methods of construction

·         Off site construction

·         Modular construction

·         What are the benefits of modular construction compared with traditional?

·         Lightweight construction with reduced groundworks and foundation loads

·         Speed of build for fast completion

·         Reduced costs due to fast completion

·         Integrated M&E building services

·         Minimum disruption with fewer deliveries to site and rapid module installation

·         Fully weather tight modular building during construction

·         Platform for latest sustainability technologies (rainwater harvest / grey water recycling, solar water heating and power, and CCHP systems)

·         What are the benefits of Corus Living Solutions modular construction?

·         Tight engineered tolerances of modular manufacture and installation

·         Reduced site finishing - modules fully finished and painted at factory

·         Directly employed site team, maximising H&S performance and build quality

·         Minimum waste and CO2 emissions (both in factory and on site

·         Embedded Corus leadership in sustainability in construction

·         Inventor modelling for ‘up front’ module and building design

·         Integration of façade and cladding including factory fitted (and aligned) connections

·         Cladding and roofing attached directly to roof deck without need for shimming / packing

CLS design modular buildings up to 8 storeys without need for additional stability structures.  CLS can design buildings up to 12 storeys using standard modules and separate stability structures (e.g. structural cores).  With minor structural modifications to the modules CLS can design taller buildings to meet project specific requirements.

The optimal size of the CLS module is up to 8m long, 4m wide and 3m tall (width and height to conform with transport regulations in Europe).  Multiple CLS modules can be combined to produce larger open plan rooms.

The weight of the CLS module depends upon its size – a module 8m long x 4m wide x 3m tall will weigh up to 10 tonnes with all finishes and fixed furniture installed including lifting equipment.

CLS in-house design team collaborate with the client project team (architect, structural engineer, M&E consultant, project manager, cost consultant) as an expert supplier using 3D Inventor modelling for ‘up front’ module and building design.

CLS use a concurrent design approach, utilising Design for Manufacture and Assembly (DfMA) techniques, considering manufacturing requirements at the same time as building configuration, module layout and structural design.

As a result, CLS are technical leaders in modular construction in the UK.  Our design capability includes architecture, structural and M&E building services engineering.  We can support design with SAP, BREEAM and CFSH calculations.  Our Structural Engineering partner checks all structural design loads and structural calculations.

CLS have achieved sustainability in construction by demonstrating use of light steel frame modular accommodation that maximises use of recyclable materials and minimises energy consumption in offsite manufacture, onsite construction and during use.  CLS currently achieve BREEAM ‘Excellent’ and CFSH Code Level 4. 

CLS modular construction will continue to demonstrate the following sustainability benefits:

·         Lightweight construction with reduced groundworks, foundation loads

·         Minimum disruption with fewer deliveries to site and rapid module installation

·         Minimum waste and CO2 emissions (both in factory and on site

·         Platform for latest technologies (rainwater harvest / grey water recycling, solar water heating and power, and CCHP systems)

CLS modular buildings currently achieve at least 60 minutes fire rating and are designed to meet the particular fire strategy requirements for each project.

CLS modular buildings currently achieve BREEAM ‘Excellent’ and will meet CFSH Code Level 4.

CLS modular construction is currently designed to achieve U-values less than 0.25 W/m2K (wall) and 0.22 W/m2K (floor) to meet BREEAM ‘Excellent’.  CLS modular buildings are designed to meet project specific requirements and will meet CFSH Code Level 4 with
U-values of less than 0.20 W/m2K (wall and floor).

CLS modular buildings currently achieve less than 8 (m3/h/m2 at 50 Pa) to meet BREEAM ‘Excellent’.  CLS modular buildings are designed to meet project specific requirements and will meet CFSH Code Level 4 with air tightness values of less than 5 (m3/h/m2 at 50 Pa).

CLS design and manufacture modules to client specification with:

·         Room M&E including power, light and heating

·         Service riser M&E including drainage to the soil stack

·         Service riser access doors

·         External and internal windows and doors

·         Internal wall finishes and joinery, ceiling finishes, tiling and floor finishes

·         Paint and decoration

·         Bathroom and kitchen fittings

CLS can install modular finished bathroom and kitchen pods to client specification.

CLS install M&E within both room and service riser ready to connect to incoming M&E building services.

CLS current manufacturing capacity is 3,000 modules per year (on a two shift pattern), with the ability to increase production to 4,500 modules per year (with a third shift).

CLS module transport uses a combination of rigid and articulated trucks, preferably delivering 2no modules on articulated flat bed trailers to minimise carbon footprint.

CLS directly employ its own installation team and has full responsibility for site management of the modular installation.  CLS site team are CSCS registered and multi-skilled including module erection, fire stopping, corridor lining, M&E building services connection, and decoration. 

CLS transport partner, access systems and crane sub-contractor partners are fully integrated with our installation team.  CLS can share access systems and crane resource with supplier partners (e.g. plant room, cladding and roofing) and with main contractors on larger projects.

CLS modular buildings up to 8 storeys do not need additional stability structures.  CLS modular buildings up to 12 storeys would require separate stability structures (e.g. structural cores).  CLS modular buildings that are taller would require minor structural modifications to the modules.

As an example, CLS currently deliver and erect a 54no module core of a building in less than a week, leading to building handover (including M&E and plant room, cladding and roofing) in 12 weeks (compared with 32 weeks for traditional construction).

CLS modular buildings can be erected on various foundation types.  The lightweight construction lends itself to innovative and cost effective foundation solutions (e.g. screw pile, thin podium slabs / transfer decks).  CLS collaborate with foundation specialist contractors as required for the project.

CLS module can support many façade and cladding finishes.  CLS can advise on the most suitable cladding options for the modular building (e.g. rainscreen, render, terracotta, traditional brick and blockwork). 

All cladding options can be attached directly to the CLS module structure using factory fitted (and aligned) connections.

CLS module can support many roofing options.  CLS can advise on the most suitable roofing options for the modular building (e.g. single ply, green roof, modular light steel, traditional truss and tile). 

All roofing options can be attached directly to the CLS module structure without need for shimming / packing due to the tight engineered tolerances of modular manufacture and installation.

CLS operate an Incident and Injury Free Policy and to date CLS has achieved nearly one million hours worked in our factory and on site without a single lost time injury.  CLS were awarded Best Trade Contractor 2007 for Safety and Environment performance by Aspire Defence.

CLS assess the health and safety record of site sub-contractor partners and supply chain by ensuring their compliance with independently reviewed safe systems of work for compliance with Corus requirements.

Registration to ISO 9001 (Quality), ISO 14001 (Environment) and OHSAS 18001 (Health & Safety) by end 2008. Q Mark accreditation to NHBC by end 2008.

CLS hold the following insurances:

·         Employers' Liability Insurance £10m

·         Public and Products Liability £10m

·         Professional Indemnity £10m

CLS can support building maintenance following construction of the modular building.

CLS have commissioned an independent study to compare whole life costing of CLS modular construction compared with traditional construction.  This will include an appraisal of the carbon footprint of CLS modular construction.

Current construction cost comparison indicates a cost premium of around 10% for CLS modular construction, usually justified in terms of the programme timing benefits.  However, it is CLS strategic intent to become the lowest cost manufacturer of modular buildings and as a result eliminate this modular cost premium.  Construction cost is dependent upon the specific project requirement, and the modular element of a completed building typically accounts for up to 50% of the overall project cost.