Sustainable external envelope solution supports net-zero logistics

Hathaway and Building Systems UK have collaborated to design, supply and install the external envelope of a new logistics and distribution facility on the banks of the River Mersey in Birkenhead.  

ARC 500, said to be the largest distribution and production unit in Merseyside, is a new 494,750ft2 facility designed to accommodate large-scale logistics operations. Its strategic location offers excellent access to the M53 motorway and the Port of Liverpool, making it an ideal choice for businesses seeking a well-connected hub.  

Hathaway specialises in the design, manufacture and installation of roof and wall cladding systems, while Building Systems UK, a Tata Steel enterprise, offers comprehensive building envelope solutions such as insulated roof and wall panels, site-assembled systems, profiles, structural roof and floor decking, and steel processing services.  

Appointed by Winvic Construction as part of the delivery team, both companies are committed to ensuring ARC 500 is constructed as a net-zero carbon facility. The project aims to achieve significant environmental, social, and governance (ESG) credentials, including a BREEAM Excellent rating and an EPC A+ target, adding a valuable economic asset to the ARC 500 Birkenhead Freeport.  

As part of the Green Supply Chain, Hathaway works closely with Winvic to develop sustainable product solutions with a focus on carbon reduction and energy-efficient materials. The primary objective is to minimise the embodied carbon emissions across the entire lifecycle of projects. 

Shaping the future 

As the key supplier for the ARC 500 project, Building Systems UK, provided a complete building envelope solution. This included Trisobuild site-assembled roof and wall systems, along with a newly developed profile designed specifically for the building’s office areas. 

Building Systems UK also developed a new external façade profile specifically for the project, conducting fire and weather testing, and producing a specific Environmental Product Declaration (EPD) for the profile to ensure it met all required sustainability and safety standards. 

Building Systems UK’s core mission is to ‘shape the future of sustainable buildings’ through transparency and thorough environmental reporting. Its EPD program allows the generation of project-specific EPDs tailored for their unique specifications and requirements.  

Building Systems UK also holds Responsible Sourcing certification under the BES 6001 standard. This commitment to environmental transparency and responsible sourcing significantly contributes to achieving sustainability goals, such as obtaining credits for a BREEAM Excellent rating, which was targeted for the ARC 500 project.  

Driving down emissions 

Building Systems UK’s manufacturing facility in Shotton, North Wales, is located just 15 miles from the ARC 500 project site, which significantly reduced delivery emissions in line with the project’s sustainability goals. 

To further decrease carbon emissions and support the transition to net-zero construction, freight deliveries for the project were conducted using bio-fuelled vehicles. Switching to Hydrotreated Vegetable Oil (HVO) fuel for these deliveries resulted in a significant reduction in CO2 emissions compared to fossil-fuel diesel. Additionally, Hathaway also supplied HVO fuel for on-site plant and machinery, which can help reduce associated emissions by up to 90%. 

Tough innovation 

New innovations are essential in Hathaway’s journey towards achieving their net zero target. One new technology that came into its own on the ARC 500 project is ToughCAD, which offers indestructible site plans, drawings, and project information that are both weatherproof and recyclable. 

ToughCAD was selected for the ARC 500 project not only for its sustainability and environmental benefits, but also for the convenience and efficiency it provides during cladding installation. The weatherproof and indestructible qualities of ToughCAD ensure these documents remain intact throughout the project’s duration, reducing the need for replacements. Its recyclability at the end of life is another significant benefit, contributing to reduced waste sent to landfill. 

These innovations and collaborative efforts underline Hathaway and Building Systems UK's commitment to leading the way in sustainable construction practices while achieving project goals efficiently and safely. 

www.buildingsystemsuk.co.uk