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Deceuninck fabricator Dempsey Dyer played a significant role in the completion of The Pastures, a £168 million student accommodation project in Colchester.

Split across five new buildings, The Pastures brings an additional 1,262 student bedrooms to the Colchester campus.

Thanks to Dempsey Dyer’s lose working relationship with the client, Bouygues, the fabricator was invited in at the design stage to offer advice on the project’s product specification and installation.

“We contributed positively to the windows’ design (switching from aluminium to PVC-U), adopted new ways of interfacing with the buildings’ structure, switched to new installation methods as work on site began and provided on-site management to ensure the project ran smoothly,” says Dempsey Dyer’s MD Peter Dyer.

Dempsey Dyer designed, manufactured and fitted 2015 frames, which is the equivalent of 4,300sq.m of window area.

 

Concrete commitment

Very early on the project, construction shifted from a modular build to a reinforced concrete design, with windows installed within a steel frame system.

 

Aluminium alternative

“Our positive relationship with all stakeholders allowed a smooth transition to this very different construction method without any delays to site,” says Dyer. “Windows for this type of project are typically aluminium, yet we successfully proposed a PVC-U alternative. This involved overcoming an issue of fitting external aluminium louvres to the PVC-U frames, which is unusual because this is typically aluminium to aluminium. We also had to demonstrate that these windows would also interface seamlessly with the façade by using a breathable membrane applied by us to the perimeter of the window creating an airtight line back to the facade.” 

 

Wind loading

Dempsey Dyer worked closely with its systems supplier Deceuninck to calculate wind loads and U-values. This is a vital requirement for commercial projects such as The Pastures – and it helps create a stronger relationship between main contractor and sub-contractor because responsibility is shared, according to Dyer. He says: “All product designs and structural calculations to evidence our compliance were presented early to the client, along with samples. Despite the fact we were outside of any contractual agreement at this point, we were committed to the partnership ethos of design and build. And because this was still an exclusive relationship, we could go back to our supply partners to develop the best product for the job.”

 

Tilt and turn

The tilt and turn windows were made using Deceuninck 2500 profile in RAL 7016 Anthracite Grey. This was a critical component since it closely replicated aluminium for planning purposes.

The units were made by Euroview. They were double glazed using SKN175 Cool-Lite from Saint-Gobain Glass, which has a g-value of 35 to help prevent overheating. The internal pane included an 8.8mm acoustic interlayer to help achieve a sound reduction of Rw40. U-value required was 1.4W/m²K.

Tilt and turn hardware from Maco was used, marine grade stainless steel fixings were specified and Illbruck sealing tape was used as part of the interface between window and structure.

 

Logistics

“Since we offered a full turnkey window solution, we were able to offer a design, production and installation schedule that suited the client, without having to involve extra parties, which could introduce extra points of potential error not least around responsibility for goods during the construction phase,” says Dyer.

“As the site operated a strict just-in-time product delivery policy, with very limited storage space (there were 20 sub-contractors involved in the project’s construction), we worked to a 75 frames per week schedule.

“Originally, each of the five blocks were scheduled to have their windows fitted in turn on a floor-by-floor basis but then changed to a vertical flow. This was because mast climbers were introduced to replace scaffolding. Not only did this complicate deliveries to site, it meant closer contact with other trades and even less margin for error.

“One knock-on effect was that we decided to fit more products in our factory, such as end caps, couplers and trickle vents, to speed up installation and create further efficiencies on site.”

Dempsey Dyer also supplied two full-time employed senior site supervisors to support its installers and help meet commitments.

Dempsey Dyer is frequently approached by Bouygues to become its fenestration partner, often invited in at the design stage. The Pastures is a perfect example of how the commercial fabricator provides a full turnkey windows package, including design, manufacture, delivery and installation.

 

Picture: The Pastures student accommodation in Colchester.

Article written by Cathryn Ellis
17th January 2024

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