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East Village - The Olympic Housing LegacyThe East Village in Stratford is London’s newest neighborhood and is a shiningexample of how Architectural Precast Cladding is the material of choice fordelivering high quality homes with a lasting legacy.

The creation of theOlympic Village nearStratford, London,represented the most

intense programme of high densityhousing construction the UK hasseen for decades. An incredible 67housing blocks, with a total of 2,818apartments, were built in just 18months - a rate of more than fivehomes a day.

Inevitably comparisons have beenmade with post war building boomsof the fifties and sixties - but whilehistory has revealed the untestedconstruction techniques used onmany of those schemes to have beenseriously flawed, the Olympic villagewas conceived as an exemplar of allthat is best about modernconstruction.

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Founded firmly on the promise that 2012 would 'be thegreenest Games ever', London's successful bid for the Gameshad emphasized the long term use and benefits to which theOlympic infrastructure would be put, and ‘Legacy‘ was key

to London finally getting the nod ahead of its rivals."That meant that sustainability was a consideration in everything we

did," says Paul Hartmann, project sponsor for the Olympic village with theOlympic delivery Authority (ODA).

"But with the eyes of the world upon us it was also important that weused high quality and proven materials that would perform well and lookgreat. And they simply had to be reliable as clearly we were working to avery inflexible deadline."

Most of the athletes’ accommodation has now been converted intohomes for rent or sale and East Village, as it is now known, is rapidlybecoming the desirable new neighbourhood envisaged by the ODA. Strollits parks and courtyards today and the part played by pre-cast concrete orreconstituted stone facades is clear to see. The vast majority of the 67blocks feature reconstituted stone cladding, but it is here in many differentforms. In fact, East Village could almost be seen as showcase for thedazzling variety of precast from which designers can now choose. There aredifferent shapes and textures, different colours, window panels, door panels,balconies and even a stunning reproduction of the Elgin marbles - allfashioned from modern, high quality pre-cast. But as Hartmann explains,this was not prescribed by the ODA's projects design panel.

"We didn't want a zoo of buildings, but nor did we want all the blocksto look the same, so architects were given a palette of colours and styles towork with." he says. "They all came up with their own way of workingwithin that - it just happened that precast was the way most chose to go."

Hartmann adds that speed, economy, and reliability were key reasonsfor this. Produced under factory-controlled conditions, often withwindows or doors already fitted, pre-cast units remove a substantial part of

the construction process from the vagaries of the weather and the variablesite conditions. And with each panel quality controlled before leaving forStratford, contractors could be confident that each would do its job.Facades were speedily erected, meaning that dry trades started early in thebuild process.

And the results certainly found favor with the critics. The FinancialTimes' architecture correspondent, Edwin Heathcote, commented:"There are many things to cheer (including) ... a material palette of castconcrete panels that eschews whacky colours." The Observer's RowanMoore agreed, noting that the Village was "made of solid, enduring-looking stuff" with no "ticky-tacky cladding".

Techrete provided more precast to the Olympic village than any othersupplier, delivering a grand total of in excess of 8000 units in just 18months. It was involved on six of the nine housing plots, specificallyproviding all facade precast to plots N01, N03, N07, N15 and then takingover plots N02 and N04 after suppliers to those sites suffered financialdifficulties.

"Techrete were great," says Hartmann. "Crucially they had thecapacity we needed for sites of this scale, with two modern factories, and anearly appreciation of what would be required here. They were also ready tolearn and respond quickly to our requests for things to be done in a certainway."

He adds that Techrete’s genuine understanding of sustainability meantthat its production process was well set up to reduce the environmental costof its products. “Add that to the fact that precast is an extremely long-lastingand low maintenance, and you have a product which fitted well into ouroverall drive for the Village to be sustainable in the longer term,” saysHartmann.

As conversion of the Village to homes nears completion, more housingis being built on the site. It's no surprise that once again, pre-cast cladding isset to feature strongly in this, the housing of the future.

An Overview of Techrete’s Scale and Scope of Work at the East Village, London

N1

1597 Techrete Panels

Area: 17,290 m2

Architect: Denton Corker Marshall

Architects

Main Contractor: Lend Lease

N2

1035 Techrete Panels

Area: 8,866 m2

Architect: Lifschutz Davidson

Sandilands Architects and KDS

Associates

Main Contractor: Ardmore

N3 & N4

2065 Techrete Panels

Area: 17,199 m2

Architect: Patel Taylor Architects

Main Contractor: Lend Lease

N7

1757 Techrete Panels

Area: 19,050 m2

Architect: Glenn Howells Architects

& Partner Hudspith Architects

Main Contractor: Lend Lease

N15

1396 Techrete Panels

Area: 13,680 m2

Architect: Glenn Howells Architects

& Niall McLaughlin Architects

Main Contractor: Lend Lease

N1

N2

N3

N4

N7

N15

0504

Techrete designed, manufactured and installed the great majority of the architectural precast façade, totaling over 8,000 panels

Elgin Marbles

is required to make "The'positives' for the moulds."

To create these, Techreteteamed up with LondonMetropolitan University, possessorof one of the largest 5-axis C&Cmachines in the UK. Replicas ofthe Marbles were then machinedfrom fibre-board. Some of thelargest pieces had to be made intwo or three sections with eachpart taking up to 21 hours to make.

Taking up the story, Techrete'sconstruction director, HenryClifford, says: "The five imageswere made in five different sizes -

so in fact we had 25 differentmoulds each made from rubberand supported by a fiberglassbacking.

"Aggregate and sand werecarefully chosen to produce thecreamy sandstone finish requiredby the architect, and the panelswere then manufactured underfactory-controlled conditions atour plant in Lincolnshire."

Finally, the Elgin units were setinto larger timber moulds to createthe final ‘sculpted’ facade panels.Says Clifford: "These varied in sizefrom depending on their function

Few aspects of the Olympic Villageattracted quite as much mediaattention or critical acclaim as thestunning reproduction in concreteof reliefs from the renowned Elginmarbles.

Precast units measuring up to6m in length and each depictingone of five of the scenes, which

originally graced the Parthenon inAthens, were used to clad two ofthe residential cores on Plot N15.

Designed by Niall McLaughlinArchitects, the 'Elgin panels'showcase just how adaptableprecast concrete can be, and how itcan be made to work in animpressive range of aestheticpossibilities.

"The Elgin marble panels weretechnically quite demanding - bothfor ourselves and for Techrete,"says Simon Bishop, associate witharchitect Niall McLaughlin. "Ourfirst job was to visit the British

Museum and use 3D scanningtechnology to create a digital imageof the marbles from the originals.It was then over to Techrete to turnthat information into solidcladding panels."

A key challenge for Techretewas that the reliefs involvedundercuts - details which cut backon themselves and prevent the useof straightforward rigid moulds."Shapes like this require flexiblerubber moulds that can be peeledoff once the concrete has set," saysBishop. It also means thatespecially sophisticated machinery

Photos

5/6. Cutting model

board on 5 Axis

machine

7. Elgin panel

loaded to go to

site

8/9. Elgin panel

on N15

on the building - but many werequite substantial, weighing up tofour tons each."

The results are quite spectacular- winning plaudits from diversesources including London Mayor,Boris Johnson, as well as an awardfrom the Concrete Society.

Says Bishop. "We were reallypleased with the way the projectwent. Techrete performed a difficultjob very efficiently and based on therelationship we forged at theOlympic Village we continue towork with them on a range ofprojects."

Photos

1.Elgin panel in

Techrete yard

2/3 Scanning in

progress in British

Museum

4. British Museum

scanning in

progress

9

0706

5

6

7

8432

1

The Elgin Marbles -Recreated inStratford

Case Study

vertical emphasis. A system wasdeveloped of setting out vertical lineson the panels through the use ofcurved timber batons laid in themould. These were moved around togive different patterns with the samelanguage giving a subtle but effectivefeature economically.

Unlike many developments, someof the most striking panels are reservedfor the courtyards. On N07 PanterHudspith Architects developed theidea of having large windows with thefaçade representing curtains beingdrawn across them. Using precastallowed the Architect to have heavilyrecessed, fluted panels of a red finishwith integral white surrounds. Thisgives a very effective façade appreciatedby all that see it.

In Summary, a precast façade can offerin terms of finish:

• Natural colours with a depth of finish

• An almost endless variety of Textures

• Complicated shapes• A wide selection of bricks and

mortar colours• Complicated Brick Coursing

including stack bonding and vertical coursing

• Neat, controlled movement joints

Photos

Main imageTechrete panels

being erected

BottomAthletes Village

Multi Coloured PanelsWith precast concrete façades it ispossible to have a number of colourswithin one panel. This wasdemonstrated on plot N01 byDenton Corker Marshall Architects.The intent was to break up thefaçade with both a change in colourbut also a change in texture andchange in plane all within one panel.

Techrete were able to develop apanel system that allowed all of thisto happen within one wall panel. Ifone looks at the detail, the basecolour of the panel is a clean white,using a white limestone fromNorthern Ireland. This iscomplimented by a recessed panel ofa different colour, texture and depthto play with light and shadow. Asyou move around the building thecolour changes in the inset panel.The texture is changed to a ribbedfinish to add interest. The colourswere developed for the Architect bya process of preparing samples usingour knowledge of stone, aggregateand pigments to achieve the desiredcolours. Techrete have a largeselection of standard samples thathave a proven track record in useand cover all colours. Sometimesthese standard colours can betweaked to meet an individual taste.Here a warm buff and a clean greywere selected as well as using whitein a vertical rib on some panels. Wecan offer developers and their designteams our years of experience increating a façade of consistent colourthrough our expert knowledge ofour materials and strict control ofthe manufacture process.

These effects can create a strikingfaçade without adding considerablecost to the project.

Roach Bed and Textured PanelsN03 by Patel Taylor Architects had awide range of colours and finisheson the plot to distinguish betweenthe different elements of the plot.

For the plinth the Architect wantedto use natural stone and had selectedPortland Roach bed which is knownfor its deep shelly texture. Techretehave previously used this stone onnumerous buildings including theBBC head quarters in London andthe House of Fraser anchor store inBristols prestigious Cabot Circusretail centre. During the valueengineering process, familiar to allprojects, the cost of natural stonewas deemed prohibitive and theRoach stone was challenged by thePQS. Techrete, with our knowledgeof using detailed rubber form linersstepped in and offered to develop an

alternative to natural stone by usingreconstituted stone. Techrete hassignificant experience of workingwith various types of rubber mouldsand we set about a programme ofdevelopment to produce samples forpresentation to the Architects andODA.

As is seen in the attachedphotographs, natural stone sampleswere taken and the rubber mouldswere produced to give a randompattern to the stone as wouldhappen in the case of natural stonebeing used. The results surprised thearchitect in terms of their qualityand consistency and were adoptedfor use in the project. Significantchallenges were presented by thejointing which was an expressedtype of joint which required verydelicate production techniques andsubsequent handling to prevent anydamage. The results as seen on theattached photographs and isstunning and gives a very viable costeffective alternative for buildings ofthis type where the budget willsimply not stretch to the use ofnatural stone. The innovation andexperience shown by Techrete indeveloping this system is evident onthis project.

In adding further detail to thefaçade the Architect wanted to adddepth to the upper panels adding a

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Replication of RoachNatural Portland Stone inArchitectural PrecastA challenge was set for Techrete to produce ArchitecturalPrecast equivalent to Roach & Portland Stone.Techrete has significant experience of working withvarious types of rubber moulds and set about aprogramme of development to produce samples forpresentation to the Architects and the ODA for theBuilding N3.As is seen in the attached photographs natural stonesamples were taken and the rubber moulds were producedto give a random pattern to the stone as would happen inthe natural case. The results surprised the Architect interms of their quality and consistency and were adoptedfor use in the project. Significant challenges werepresented by the jointing which was an expressed type ofjoint which required very delicate production techniquesand subsequent handling to prevent any damage. Theresult as seen on the attached photographs is stunning andgives a very viable cost effective alternative for buildings ofthis type where the budget simply will not stretch to thefull use of natural stone. The innovation shown byTechrete in developing was noted by all.

Olympic Village Exhibits a Range of Finishes

Architectural Precaster.This had a downstream effect onsome of the common suppliers toTechrete such as for fixings anderection.

Lendlease and ODAapproached Techrete about thecompletion of some of the partiallycompleted works. In additionArdmore needed a contractor tocomplete the work on N2. Thisproved particularly challenging incoming in at a halfway point andhaving to try and match samples ona building which was at that stageone third erected. Techrete rose tothe challenge developing equivalentmixes and ensuring that thecompletion date originally intendedwas not impacted.

The loss of traditional skills andyears of experience in these failedcompanies is very much to beregretted and it is hoped that theskills can be retained in the industryby the remaining players ensuringthat they are not lost.

Design The challenge of engaging with alarge number of multi disciplinedArchitectural practices was immense.Techrete approached this by settingup individual project teams to dealwith each of the block developments.Computer modelling via Tecklasoftware was used which made theinterfacing with the groups ofArchitects very efficient.

Maintaining consistency acrossall the blocks was difficult but itfound that when any differenceswere explained to the various teamseverybody came to the party inengaging with the need for anintegrated consistent approach.

LogisticThe logistic challenge of deliveringon an on time basis to each of thePlots proved difficult. Eventuallythrough discussion with Lendleaseand the ODA it was agreed that anon site Reception facility for loadedtrailers was going to be necessary toachieve the project objectives. Thedeliveries to site peaked at 70 loadsof architectural precast per weekwhich were delivered to a centralarea on site. This Reception areawas equipped with its own shuntingfacilities which allowed for thedelivery of the loads which weredelivered on a drop and pick basis tobe subsequently re-delivered to eachof the project plots on a just in timebasis.

As familiarity grew amongst theteams and with no change of driverson the shunting vehicles theoperation quickly settled down to avery smooth flow. The centralfacility facilitated the offloading andconsolidation of transport framesfor return journeys which had a

significant impact on reducing thecarbon footprint for the job. It alsoreduced waste by the consolidationof all of the packing timbers andtransport straps and their returnefficiently for reuse. Theengagement of Lendlease in thisrevised approach was total andwithout that simply the objectivewould not have been achieved. TheLendlease personnel provedextraordinarily professional andefficient in their engagement withthis process as they foresaw thebenefits and then saw them play outin actual execution.

ConstructionOne advantage of the fact that all ofthe plots were relatively closetogether emerged very quickly inthat it allowed the ConstructionDirector to be site based and haveeasy access to each of his individualplot teams. The coordination of theconstruction between the variousplots probably proved one of themost challenging aspects of thewhole job as the demands ebbed andflowed on each of the plots withcraneage, road access, access forother trades constantly changing. Itis testimony to the onsite clientteams and to the in house erectorsthat the process ran so smoothly.

Safety also the EnvironmentThe challenges in relation to safetyand the environment were immense.The targets set were at an all timeindustry worldwide high. Theresulting performance has set worldstandards for the achievement ofoutputs on this type of project.Outputs of 200 panels per weekwere achieved taking all factors into

Technical Achievements

account such as weather, congestionetc. These were achieved within a verystrict safety regime on the plots. Theexemplary results achieved speak forthemselves.

HandoverProbably one of the most challengingaspects of this project was the need tocomplete apartments in a totallysequential manner and hand themover ready for occupation. Thelogistics challenge presented by this toLendlease was of massive proportions.The introduction of a Directors weeklymeeting over a working lunch to makesure that all significant issues got airedand that all of the project teams atDirector level knew one anotherproved to be hugely significant. Thevision of Chris Howcroft, ProjectDirector for Lendlease in setting thisup and then sticking with it throughsome very difficult periods is to behighly commended. Hisachievements in welding the teamtogether have set a new standard forapproaching large scalemultidisciplinary constructionprojects.

Financial FailureA further challenge arose during theproject when a number of specialistscontractors got into financialdifficulties.

These were not only contractorsinvolved in Architectural Precast butthe one that impacted on Techretemost was the failure of a significant

‘demands ebbed andflowed on each of theplots with craneage,road access, access forother tradesconstantly changing’

Photos

TopOlympic panels in

works

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Techrete at the OlympicsThe Olympic challenge for Architectural Precast and Techrete

Photos

TopElgin panels ready

for dispatch

RightPanel being

erected with pre-

installed windows

Right bottomOlympic panels on

yard trailers in

works

A new approachThe completion of the Village also demonstratesthe long-term legacy the Games will deliverwhen beds for athletes become essential newhomes for Londoners

T he completed structuresaccommodated 17,000Olympic and 6,000Paralympic athletes and

officials during the games.The designs also feature shops,

restaurants, medical, media andleisure facilities, in addition to largeareas of open space.

Inspecting the site, culturesecretary Jeremy Hunt said: ‘TheOlympic Village looks fantastic, It is

yet another example of how wecontinue to deliver on ourpromise to leave behind real andlasting benefits from London2012.’

LOCOG chair Seb Coe said: ‘The completion of the Villagealso demonstrates the long-termlegacy the Games will deliverwhen beds for athletes becomeessential new homes forLondoners after the Games,

creating a vibrant newneighbourhood on the doorstep ofthe Olympic Park.’

The Olympic DeliveryAuthority (ODA) agreed to sellthe village to Delancey and QatariDiar for £557million. The site isbeing transformed into housingfollowing the games. As many as1,379 of the units are owned byTriathlon Homes.

Architects

CF Møller, Denton

Corker Marshall,

Glenn Howells, Ian

Simpson,

Lifschutz Davidson

Sandilands,

Niall McLaughlin,

Panter Hudspith,

Patel Taylor and

Piercy Conner.

New Homes forLondonersSource: ODA

Some Facts• A complete neighbourhood of

2,818 properties, including 1,379affordable homes

• Family housing with nearly 1,000three and four bed homes

• New homes spread across 11 individually designed residential plots in one of the best connected parts of the capital, providing neighbourhood character and choice

• New homes built around private courtyards with car parking

• New homes built to Code for Sustainable Homes Level 4 and designed for modern, sustainable living, with fittings and finishes of the highest standard

• Six future development plots withexisting outline planning consent and the potential for 2,000 open market homes to be developed, together with retail floor space and associated uses

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O lympic Village investorannounced with plansfor a newneighbourhood for

London, £557m deal securessignificant public sector returns andworld-class legacy owner for Village

The Olympic Delivery Authority(ODA) announced that contracts havebeen signed with the joint venture ofDelancey and Qatari Diar for thepurchase and long-term managementof the Olympic Village. The jointventure will work alongside TriathlonHomes who will manage theaffordable housing in the Village.

Architects

CF Møller, Denton

Corker Marshall,

Glenn Howells, Ian

Simpson,

Lifschutz Davidson

Sandilands,

Niall McLaughlin,

Panter Hudspith,

Patel Taylor and

Piercy Conner.

The Village, which lies adjacent tothe Olympic Park, will create a newneighbourhood for east London,delivering the best of city living all inone place - high-quality new homes,education and healthcare facilities,new parklands, public squares andopen space, with transport linksmaking it one of the best connectedparts of the capital.

The Village will deliver 2,818new homes, including 1,379 alreadypurchased by joint venture TriathlonHomes to become high-qualityaffordable housing. Delancey andQatari Diar will now acquire theODA’s interests in the remaining1,439 homes which will becomeprivate housing, along with sixadjacent future development plotswith the potential for a further2,000 new homes. Delancey andQatari Diar will invest around £557million for the purchase and long-term management of the OlympicVillage. The deal also includesarrangements to provide a futureprofit-share for the public sector.

The majority of the 1,439private homes in the Village are tobe let on a rental basis, instead ofbeing sold, with the ownershipremaining with the Delancey andQatari Diar joint venture. This willcreate the first UK private sectorresidential fund of over 1,000homes to be owned and directlymanaged as an investment.

ODA Chief Executive DennisHone said: “This deal will deliver a

significant return to the public purseand a first-class owner for theOlympic Village. It secures twoleading property investors with theexperience and expertise needed tomake the Village one of thestrongest legacies from the Games.The Village will deliver the best ofcity living all in one place with high-quality new homes, education andhealthcare facilities, new parklands,great transport links, public squaresand open space.”

Secretary of State for Culture,Olympics, Media and Sport JeremyHunt said: “This is a fantastic dealthat will give taxpayers a great returnand shows how we are securing alegacy from London’s Games. TheVillage will be the centrepiece of anew vibrant East Londoncommunity and I am confident thatthese experienced property investorswill deliver a modern, spacious

By John Doe an architect and professorat the University of London, UK

The Village hasdelivered 2,818new homes tobecome high-quality affordablehousing

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