units including precast walls, ‘Hellerup’ stair, stairs, lift shafts, floor planks and columns were manufactured to the highest quality standards and delivered to site and installed with maximum efficiency.


The precast concrete frame was built over a 27-week period between October 2022 and May 2023, with a large crane lifting the panels into position on arrival to site from our Byley factory in Cheshire. Some of these precast panels were particularly large, with seven measuring 12m in length for the construction of the three storey high dining hall.


Quality focus key to success


For BAM Construction, the project was the first Passivhaus build of this type they had undertaken in Scotland, but they were able to draw on extensive experience from within the group, chiefly in respect of projects in South West England and Germany. Their approach from the outset was to create the pre-cast structure not just to be ‘a little bit more airtight’, but significantly so.


The BAM team in Scotland recognised that the key difference between this project and non-Passivhaus building projects was intense scrutiny on quality and detailing, and the initial advice provided by their colleagues in Germany was simply put – ‘build it with concrete’. By using this material, they knew they could create an inherently airtight frame that would not have to rely on membranes and other elements.


Quality control was critically important to ensure the airtightness goals would be achieved and the project team developed processes to manage this. Fife Council’s architect, John Peden, took on the role of


“quality champion” and established a quality team. They sought to look for continuous improvement opportunities, including using lessons learned from previous projects, through dedicated quality meetings on site, quality walk-rounds, and by reviewing particular elements of work as it began or prior to roll- out.


The result of this attention to detail and continuous quality focus delivered an airtightness level that surpassed the target. In the precast concrete framed building, airtightness of 0.4 h-1 @ 50 Pa was recorded.


A very high level of airtightness was not the only benefit of using precast concrete, however. Superior acoustic performance could be achieved more easily due to the floor-to- floor spans of the precast units, and they also reduced the need for linings in the stairwells, which is a vulnerable area.


Precast concrete also enabled the building envelope to be partially wind and water-tight much earlier in the programme than would have been the case with other approaches, such as a cladding solution. This in itself has major benefits, not least helping to keep the build schedule on track amidst the uncertainty of the Scottish weather.


Lessons for future Passivhaus projects


Applying Passivhaus principles to the construction of the new Woodmill High School and St. Columba’s RC High School was an ambitious step by Fife Council, but it has delivered outstanding results thanks to the positive approach of the whole project team and a dedication to design quality. Architect’s AHR balanced the need to embed Passivhaus principles with quality from the outset and


the selection of materials, including precast concrete, contributed to achieving high thermal and acoustic performance.


Buildability was also significant in this project and here again precast concrete proved its value. The architects acknowledged that the decision to go with this material for the main building frame helped to make the build process straightforward. This in itself can have a massive impact on the success of construction projects because complexity is reduced and efficiency is therefore improved.


But one of the most important outcomes of this project is that it challenges the perception of concrete not being compatible with highly sustainable construction. The benefits of precast concrete over the lifetime of these school buildings, particularly in respect of helping to minimise energy consumption for heating and cooling will far outweigh the carbon emissions resulting from the production of its raw materials and its manufacture.


Find out more about the benefits of precast concrete at www.fpmccann.co.uk


Winter 2025 issue 4178 17


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