Elhance was appointed to carry out fire risk remediation works to an occupied student accommodation building, focusing on the removal and replacement of combustible materials within the external façade. The project addressed several areas of concern, including insulation behind a rendered façade system, insulation behind curtain walling to stairwells, combustible soffit insulation, and ACM column casings.
As the works progressed and sections of the façade were opened up, further issues became apparent. When the existing insulation was removed, we discovered that the cement particle boards beneath were cracked and had previously been sealed using a combustible mastic. This reinforced the need for a thorough approach, ensuring that not only the known risks were addressed, but also any hidden issues uncovered during the works.
Our scope included the installation of new cement particle boards, installing non-combustible insulation, and a new render system. This comprised a base coat applied over reinforcing mesh, followed by a top coat finish.
In the stairwells, we removed the existing flashings, replaced the combustible insulation behind the curtain walling, and then carefully reinstalled the original flashings to retain the building’s architectural intent.
At soffit level, combustible Kingspan insulation was replaced with compliant 100mm Rockwool. We removed the ACM column casings and replaced them with non-combustible aluminium casings. Everything was completed in line with the agreed programme, despite the logistical challenges of the project.
For ease of planning, we divided the works into three defined areas. The new render system itself was specified by the client’s architect; our role was to ensure that the supporting insulation and substrate met current fire safety requirements.
One of the key constraints was the limited projection of the existing window cills, which restricted the thickness of the new insulation. Because non-combustible insulation is denser than the original combustible material, we carried out wind load and structural assessments to confirm that the existing structure could safely support the new system.
To ensure a seamless appearance, we contacted the original installer to achieve a colour match on the new render. Although fire breaks were not required within the rendered façade system, we introduced some in certain areas, such as in a curtain wall flashing feature and behind the brickwork at the bottom of the render. This decision strengthened the overall fire safety of the building.
Alucobond soffit panels were installed onto the existing support frame. We inspected the frame in detail, added fixings where required, and carried out structural checks to confirm its suitability. The replacement Rockwool soffit insulation achieved the same thermal performance as the original construction. The new column casings were fabricated from 4mm powder-coated aluminium and fixed using the existing support brackets.
Rendering works are highly weather dependent, and completing the project during the winter months required careful planning and flexibility. As the building remained occupied throughout, we placed strong emphasis on resident safety, clear communication, and considerate working practices to minimise disruption.
The site was also extremely constrained, with limited space for storage and deliveries. To manage this, a bicycle rack was temporarily dismantled to create a safe materials storage area.
In some areas, additional support brackets were required to accommodate changes in the cement particle board alignment. Early in the project, we worked closely with the render contractor to ensure that workmanship met the required standard from the outset.
Quality assurance was a core part of our approach. Our Site Quality Management Plan set out clear requirements to confirm that all combustible materials were removed and that replacement components were installed correctly. This included approved drawings, supporting calculations, defined inspection stages, and regular progress photography.
All imagery and records were stored within our project database, with a shared Dropbox set up for the wider project team. Images were clearly labelled by elevation and inspection stage, providing transparency throughout the works. At completion, all quality information was passed to our team responsible for producing the Operations and Maintenance manual, which was issued to the Employer at Practical Completion.
This project demonstrates Elhance’s ability to deliver effective fire risk remediation within an occupied building, balancing technical requirements with the practical needs of residents.
Through careful design, clear communication, and rigorous quality control, we delivered a compliant and durable façade solution that significantly improved fire safety, while preserving the building’s appearance and ongoing use.