Staffordshire, New-Build Primary School Facility

Project Overview

Background

In 2024, as part of a significant 400-acre sustainable urban extension in Burton on Trent, Staffordshire County Council and the John Taylor Multi-Academy Trust oversaw the construction of Branston Locks Primary & Nursery School. The new-build facility was designed to meet the Department for Education’s (DfE) stringent sustainability objectives, aiming for Net Zero Carbon in Operation at handover.

To achieve these goals, the project, led by main contractor Tilbury Douglas, prioritised a high-performance building envelope. The specification called for an advanced external wall insulation (EWI) system that would provide superior thermal efficiency while meeting the highest safety standards for a modern educational environment.

Brief

The design required a robust, non-combustible EWI system capable of being installed over a lightweight steel framing (SFS) structure with sheathing boards. Beyond thermal performance, the system needed to be resilient enough for a school setting and aesthetically compatible with the master developer’s vision for the wider Branston Locks community.

Permarock technical staff supported the project team by providing comprehensive design advice, including thermal calculations (U-values) and condensation risk analysis. They also conducted in-situ pull-out tests to verify the security of fixings into the sheathing board substrate and provided project-specific training for the approved specialist installers.

Design and Specification:

The chosen EWI system comprised:

The system utilised Permarock Mineral Fibre Dual Density (DD) Insulation, specified at a significant thickness of 250 mm. This dual-density technology features a high-density outer surface to provide a firm base for fixings and render, while the more flexible underside accommodates any minor irregularities in the substrate. The boards were secured using a combination of high-polymer-content adhesive and mechanical fixings to ensure long-term stability.

The exterior was finished with Permarock SiliconeUltra K-Finish (1.5 mm grain size). This finish was selected for its exceptional water repellency properties. By incorporating nano-quartz technology, the render resists dirt pick-up and inhibits the growth of algae and fungi, ensuring the school maintains its “as-built” appearance with minimal maintenance.

Performance and Sustainability

The Permarock Mineral Fibre system is a key contributor to the school’s Net Zero Carbon goals. The insulation boards are manufactured to EN 13162, are CFC and HCFC free, and have Zero Ozone Depletion Potential (zODP) and Zero Global Warming Potential (GWP). With a thermal conductivity of 0.036 W/mK, the 250 mm thick system provides a highly efficient thermal barrier.

Crucially for a school, the system achieves an A2-s1, d0 reaction to fire classification (EN 13501-1), the highest level of fire safety for a system of this type. It is also BIM Level 2 compliant and holds an Ecopoints score of 0.10 (m²), representing an ‘excellent’ environmental rating.

Result:

The school successfully opened its doors in September 2024, standing as a centerpiece of the new Branston Locks community. The use of the Permarock Mineral Fibre system has resulted in a building that is not only architecturally striking but also exceptionally energy-efficient.

By meeting the Net Zero Carbon in Operation target, the facility minimises its environmental impact and reduces ongoing energy costs for the Trust. The durable, fire-safe, and low-maintenance facade ensures that the school will remain a safe and inspiring learning environment for the children of Burton on Trent for decades to come.

Project
New Build / Education
Client
Staffordshire County Council / John Taylor Multi-Academy Trust
Installer
Rendserve
Substrate
LGSF with Sheathing Boards
System
Permarock Mineral Fibre External Wall Insulation Systems
Finish 1
Permarock SiliconeUltra K Finish