Walton Court Gardens in Surrey is a new development of one-, two-, and three-bedroomed apartments, and three-bedroomed townhouses set within the leafy suburbs of south-west London.
375 new homes now sit on the site of the former Birds Eye headquarters in Walton-on-Thames, which has stood empty for more than a decade.
Shortlisted for the Housing Design Awards, the pattern of the façade drew inspiration from the design of the original building, and the architects aimed to create a strong sense of community for future residents. Streets and open spaces are lined with new and existing mature trees, and there are convenient transport links via road, rail and Heathrow Airport. Residents also have access to a range of amenities on their doorstep, including a cinema, golf club and schools.
Our approach
We collaborated closely with our supply partners to provide a comprehensive solution to Block H of the Walton Court Gardens Project, supplying and installing more 1,163 new energy efficient PVC-U windows and doors. This included 463 fully reversible windows, 464 casement windows, 149 French doors and 87 residential PVC-U doors.
Very early in the design phase, developer Crest Nicholson discussed the demanding window specification with us, after we had manufactured and supplied 2,514 windows and doors on phases 1 and 2 of the project.
Key to the success of the project, we demonstrated that our energy efficient windows can be supplied in Bronze Platin on white interior, which was a specific requirement from the client. Working closely with systems company Epwin, we provided a series of drawings and calculations that could satisfy the demands of the brief, including: wind-load calculations; barrier load calculations; thermal performance calculations; window and door construction details; and purge ventilation calculations.
This was crucial on this project as the large floor-to-ceiling windows measured 1,590mm x 2,650mm, and 1,810mm x 2,650mm, and were installed up to four storeys high.
The Bronze Platin foil was made to order and sourced from Germany. Since we managed the design, manufacture and installation of the windows and doors, we could incorporate the long lead time on this component part without the risk of it delaying the project.
We also worked very closely with our sister company Acorn Aluminium, who were involved in the curtain walling element of the project, again allowing us to put systems in place that would ensure the project ran smoothly, and without delay.
“Many of the windows are at height, and provide a floor-to-ceiling barrier. Following detailed wind and barrier loading calculations, we designed Fully Reversible Profile 22 Windows that incorporated steel reinforcement to allow the large frames to be constructed as one without being split and coupled. Fully reversible windows will provide the homeowners with both ventilation and safe, easy cleaning access.”
Stanley Richardson, Commercial Window Group’s Sales Manager.
Considerations
Energy efficiency was a key focus on the project, and the windows comfortably met the 1.2W/m2K U-value required, thanks to the advanced Profile 22 profile from Epwin. The windows were factory-glazed with toughened, laminated argon-filled units using Planitherm One glass from Saint-Gobain Glass, which also provide high levels of thermal performance and security.
Aluminium panels replaced the glass in some of the frames, powder-coated in Bronze Platin – to match the windows – which we sourced and installed.
The windows were installed using a structural coupling section, which is a steel box that goes on to the back of the frame to give it rigidity. This meant the large frames could be constructed as one without being split and coupled. This also required an unusual fixing method that included chemical fixing and a diamond drill, which we were able to easily incorporate into our workflow. This was alongside installing the EPDM weather seal membrane, which gave us control over the overall weather performance of the façade.
We also supplied 381 French doors, which suited perfectly with the windows, and the aluminium entrance doors.
Finally, site access was very tight, which could have interfered with delivery schedules and overall time frames. To overcome this, we devised a new method of delivery, which involved transporting stillages on a flatbed truck. These were then easily lifted into place using the site crane.
“We often offer a technical point of view early on in a project to make sure all aspects are considered and that projects are priced correctly. The last thing they need is unforeseen costs further down the line.
“The beauty of this project is that the partnership between us as the systems company and Emplas Commercial, a partner of the Commercial Window Group Commercial Window Group as the manufacturer/installer, is that all specifications, details and requirements are met. We also take part in site visits, so that any potential problems are ironed out early on, and don’t negatively affect the build during the installation phase.”
Phil Parry, Technical Director, Epwin.
Summary
- Client: Crest Nicholson.
- 375 one-, two-, and three-bedroomed apartments, and three-bedroomed townhouses completed in 2023.
- Close collaboration with developer Crest Nicholson during the design phase
- Became part of the design team
- Value-engineered a project solution so most windows were PCV-U, instead of aluminium
- Saved money without compromising on performance and functionality
- Providing drawings and technical calculations
- 1,163 new energy efficient Profile 22 windows and doors, factory-glazed with toughened, laminated argon-filled units using Planitherm One glass from Saint-Gobain Glass.
- 2W/m2K U-value.
- Bronze Platin foil and aluminium powder coating, made to order from Germany.
- Unusual fixing methods, including box steel reinforcement and chemical fixings.
- Engineered site delivery solutions to overcome tight access.
Closing thoughts
“The focus is very much on those top-end projects that specify and demand only the very best. Working closely with Crest Nicholson, we were able to value engineer a project solution so the majority of windows were PCV-U, instead of aluminium, saving money without compromising on performance and functionality.”
Stanley Richardson, Commercial Window Group’s Sales Manager.
As a result of successful project delivery to date, Emplas has been invited to help complete the remaining phase of the development, which underscores the well-deserved reputation Emplas has built over the whole Walton Court Development.
