The Knoll 2

An OFP Case Study: The Knoll

A four storey residential nursing project

Overview

The Knoll, Nursing Home, Deal, Kent

•4 storey build featuring a lift shaft throughout

•38 residential rooms

•2 storey ‘day room’ area

•Nurses office

Stage 1 – The plans

1. Elevations

The architectural drawings are sent to OFP in CAD format for the design team to look through and assign to a designer.


2. The architect’s CADs are then drawn up to suit timber frame using TRADA timber frame standards.


3. Once the architects drawings have been approved by the client the designer can start the design process.


4. When the timber frame drawings have been signed off by the client and the architect then the panels and floor cassettes can be generated.

These are accurately engineered drawings used to produce the walls in the building.

These are then sent to the production team and scheduled in to the factory.

Stage 2 – Manufacture

The completed panel drawings are added to the production package and sent to the factory for manufacture.


After the design has been completed a CSV file is generated. This works in conjunction with our optimaster saw to produce a waste managed cutting list.

1. The quantity of timber required is calculated and loaded in to the saw.

2. The saw is electronically programmed for the scheduled works.

3. The timber is efficiently and accurately cut. This minimises any waste.


4. The optimaster saw prints the exact position of each stud in the panel and its position within the building.

5. The timber is loaded in to the rack for the manufacture process to begin.

6. Each compartment is organised according to the timber reference.


7. The timber is taken from the rack.

8. The panel is laid out on the manufacture bench with the panel drawing beside it.

9. The panel is assembled in a controlled environment to the designer’s specifications.


10. The completed panel is loaded in to the plot stack.

12. The completed stack is taken to the loading bays ready to go to site…

11. The stack is checked for quality and accuracy.

Stage 3 – On site erection

Once the panels have been manufactured the erection process can begin…


Day One

The first element to go to site is the soleplate. This is the footprint of the building.

Duration: 1 day.


Day Two

Once the soleplate has been fitted the ground floor panels are delivered.

144 panels were installed over 2 days.


Day Three

Here we can see the landed and erected internal panels.


Day Four

If any steels are required in the build these can be sent as part of the production schedule.

32 steels were required in the ground floor in this project.


Day Six

Once the panels have been fitted the floors can start going in.

45 cassettes were landed in 2 days.


Day Nine

Once the cassettes have been fitted and decked the next floor can be installed.

144 panels were installed over 2 days.


Day Nine

Here you can see the external panels sheathed in OSB.


Day Nine

The first floor panels are in and ready for the second floor cassettes to be landed.



Day ElevenThe second floor cassettes are landed.42 cassettes were landed in 2 days.


Day TwelveThe cassettes are decked out. The starter plate is then laid for the next stage of panels to be erected.


Day ThirteenThe 2F panels are landed and erected.105 panels were landed in a day.



Day FifteenThe third floor cassettes are landed.17 cassettes were fitted in a day.



Day SeventeenThe third floor panels are landed.49 panels are landed in a day.


Day SeventeenThe roof trusses are also landed with the 3F panels.



Day NineteenThe roof timbers are fitted.


Stage 4 - Completion

After OFP have completed the roof and the building is signed off the second fix can begin.

Here are a number of recently completed projects illustrating OFP’s finished product…

Stage 4 – Completion



Real Estate

The Knoll 2