Specification focus: Drylining tests the water

As with other specialist sectors, the drylining sector has adopted new methods and practices that considerably improve productivity, while addressing the challenges of Building Regulations, specifically acoustics and energy efficiency.

Drylining products are now considered far more than partitioning systems. They are carriers of electrical services and, thanks to improvements in steel frame systems, offer an alternative structural solution for building design. The range of products available has also widened into areas such as ceilings, floors, moulded products and coving, motivating further increases in the market.

The UK drylining sector is now worth £2.5bn per annum and growing at a rate of 5% each year. In 2000, the market size by volume was approximately 200 million m2 and by 2010 this figure is expected to swell to 230 million m2. "It's an interesting and busy sector," explains Emma Tomlin, chief executive of the Federation of Plastering and Drywall Contractors (FPDC). "Now every major project involves drylining."

Despite its market penetration, the sector feels it could contribute more when it comes to project design and delivery. According to Nick Atkinson, sales and marketing director at Clark and Fenn Skanska, the lack of connection between the specialist contractor and designer continually causes problems. "Those in the design community have limited contact with the specialist contractor," he says. "On a regular basis, errors exist that could easily be ironed out at an earlier stage if a specialist contractor was consulted."

It is a recurring concern among drylining contractors, who believe they have more to offer than simply arriving on site to install a system specified for them. "The interface of the drywall contractor is a critical path," continues Tomlin. "The biggest issue is the interface with mechanical and electrical, and how that is managed. While the drywalling sector is lower in project cost than M&E, if there are any problems with the combination of trades it will have a knock-on financial effect which often isn't considered."

Furthermore, with just three main manufacturers in the market - British Gypsum, Knauf Drywall and Lafarge Plasterboard - all competing to offer complete solutions, specialist contractors feel they are being squeezed out of any value-added offering, having been forced to adopt a design dictated to them. "The manufacturers are keen to maintain a systems-led approach, which includes the boards, metal profiles and accessories," says Tomlin. "They don't want to go down the commodity route."

This means that specialist contractors must use every element of a particular manufacturers' system or risk invalidating the warranty. "Everything is system-based in order for the manufacturer to lock the specification down," explains Atkinson. "But at least with this approach, you know the product is satisfactory."

However, being firmly tied down to every detail of the system means that manufacturers can name their price, says Angela Mansell, operations director at Mansell Finishes. "Manufacturers provide a system warranty, but that means every single component has to be supplied by them," she adds. "They only manufacture the board, but as part of a system a contractor must use all recommended accessories. There is no technical expertise to a screw - it's all about money and margins."

Despite carrying a premium, manufacturers claim this approach provides peace of mind for both specialist and main contractor by assuring compliance with building regulations. "We firmly believe in the system approach," says Spencer Maynard, technical specification manager at Knauf Drywall. "It's the same for all manufacturers. The benefit is that we can provide thorough test data that will satisfy structural, fire and safety requirements." He confirms that if an unbranded stud was employed, the test data would be invalid. "From time to time, contractors use different screws or mastic to try to save money, but there's a risk in that saving. It's a false economy as the contractor is walking away from all the technical expertise we provide."

And it's not only the system approach that is causing a stir among specialist contractors. Supply agreements between plasterboard manufacturers and main contractors are becoming common, further diluting the influence of the specialist contractor. The largest main contractor deals are thought to include Bovis Lend Lease, Laing O'Rourke and Carillion. Maynard counters that this type of approach will pay dividends for the main contractor: "We provide a dedicated service for Carillion and can make sure that subcontractors are pricing the most efficient systems possible. We provide the design solution and spec the project, information that's then included in the tender document to give subbies good information to work from."

Supply agreements

These agreements have made inroads into the position of specialist contractors, who claim they are hindering their ability to buy better and offer opportunities to value engineer designs. "Main contractors think there's a margin to be had in our part of the supply chain," believes Atkinson. "On most projects we win, this is simply not the case."

Subbies consider the root of these deals lies in a lack of trust on the part of the main contractor. "I can understand why main contractors have decided on sole supply deals," says Mansell. "As an industry, we need to catch up in terms of procurement. Most larger specialists are almost there, but it's the smaller companies that can let the industry down in terms of professionalism."

But removing specification responsibilities from subcontractors also has the effect of distancing them from planning waste recovery. Figures from FPDC research show that waste is often caused by incorrect specification or intended use and that 20 million m2 of plasterboard is wasted due to cutting boards down to size and shape. "We'd like to see a reduction in board sizes but manufacturers aren't keen," explains Tomlin.

Knauf Drywall does offer plasterboard to any length, but it carries a 10% surcharge. Maynard says this is to make sure that unusual sizes are only specified by those who really need them. "If we started manufacturing different sizes for every contractor it would be a 'call off' nightmare and impossible to keep our warehouse stocked," he explains. He also strikes a note of caution regarding attempting to engineer waste savings, pointing out that building tolerances are not accurate enough to avoid problems and the creation of further waste. "If slab tolerances are ±25mm, then designing a pre-manufactured board to match this would be problematic. The tolerances are just not tight enough to avoid problems."

That is not to say that manufacturers aren't addressing technical issues within the industry. Largely as a result of changes to the Building Regulations there has been a shift in demand towards thicker, higher performance plasterboards to address acoustic and energy performance requirements. But these boards are heavier to lift and carry on site, which has health and safety implications. Adam Richold, marketing director at British Gypsum, says the manufacturer is taking on these challenges. "We are approaching the problem from two sides - on the one hand, our innovation team is now looking at how we can achieve higher performance from lighter-weight boards, and on the other we are moving towards narrower boards, with many of our more popular boards now available in 900mm width." He adds that the company has also ramped up its waste reduction activities and is working with customers to reduce waste and make collection simpler.

Waste recovery

Driven by the introduction of Site Waste Management Plans next April, waste recovery in the sector is gaining momentum. Lafarge, British Gypsum and Knauf all operate recycling schemes and the FPDC is working with contractors and the BRE to set meaningful targets and challenge the sector to be more waste conscious. Meanwhile, WRAP (Waste & Resources Action Plan) is looking at ways of designing out waste and minimising damage caused by distribution and inadequate pallet coverings. Maynard explains: "Right now, it's considered a good idea to recycle in a year it will be essential."

Indeed the sector is responding positively to the variety of challenges presented and continues to grow. "This year has been strong and next year should be okay, but commercial work may slow a bit in 2009," says Maynard. "Still, there's a strong possibility that this slack will be taken up by the small matter of a project out in east London."

Making sure the staff don't dry up

The drywall sector is acutely aware of the need to attract 4,000 new workers over the next five years to keep up with demand. Some 7,500 new projects with a total value of almost £190bn are projected to start in the next five years, in which drylining will play a significant part.

But as in other specialist trades, training is a contentious issue. The sector has been relying heavily on labour from Eastern Europe for the past few years just to stand still. "Without a migrant workforce, it would have been difficult to operate in the past two to three years," explains Angela Mansell, operations director at Mansell Finishes. "They're multi-disciplined and willing to travel, which is great."

However, this approach is widely considered unsustainable as it is expected that a time will come when wages in Eastern Europe will increase and the workforce will be drawn home.

There is an NVQ in drywall fixing and finishing and three training schools set up by plasterboard manufacturers. But these have a commercial emphasis and, even running at capacity, could train only 60 students a year. Emma Tomlin, chief executive at FPDC, says this lack of training could affect standards within the industry at a time when technical requirements are greater.

The FPDC has approached ConstructionSkills for help setting up a not-for-profit, employer-led training facility for the drywall industry, but has been rebuffed. "The market is big enough to sustain a training school for all levels," explains Tomlin. "But ConstructionSkills told us it's not an approach they would support. They possibly feel it would undermine what they do. It's frustrating because we pay millions in levy with nothing in return."

However, according to Mike Bialyj, director of advisory services at ConstructionSkills, the organisation recognises that the sector requires specialist and tailored support. "Specialist training is often low in volume but high in costs," he explains.

"One way we are able to support this is through our Awarding Body, which can co-ordinate new tailor-made qualifications in a short timeframe once the evidence and underpinning framework are in place."