The BBA's Agrément Certificates have been providing
authoritative and independent information on the performance of building
products for over 35 years. Every Agrément Certificate contains
important data on durability, installation and compliance with Building
Regulations, not just in England and Wales, but in Scotland and Northern
Ireland, too.
Assessment involves three distinct areas - laboratory
testing (carried out wherever possible to UKAS requirements), site inspections,
undertaken by the BBA's own Inspection Services team, and factory production
control.
Readers are advised to check the validity of this Certificate
by either referring to the BBA’s website (www.bbacerts.co.uk) or contacting
the BBA direct (Telephone Hotline 01923 665400).
1 The Building Regulations 2000 (as amended) (England and Wales)
The Secretary of State has agreed with the British Board of Agrément
the
Requirements of the Building Regulations to which wall and floor panels
can contribute in achieving compliance. In the opinion of the BBA, the
Danilith Prefabricated Building System, if used in accordance with the provisions
of this Certificate, will meet or contribute to meeting the relevant requirements.
Requirement: A1 Loading
Requirement: A2 Ground movement
Comment: The system will have sufficient strength and stiffness when
designed in accordance with sections 10.1 and 10.2 of this
Certificate.
Requirement: B2(1) Internal fire spread (linings)
Comment: The panels will adequately resist spread of flame over their
surface. See section 15.2 of this Certificate.
Requirement: B3(1)(2) Internal fire spread (structure)
Comment: The panels can satisfy this Requirement. See sections 15.1 and
15.3 of this Certificate.
Requirement: B4(1) External fire spread
Comment: The external wall panel can satisfy this Requirement. See
sections 15.2 and 15.3 of this Certificate.
Requirement: C4 Resistance to weather and ground moisture
Comment: The product can satisfy a building to meet this Requirement.
See sections 9.1 and 9.2 of this Certificate.
Delmulle NV
Waregemseweg 146
B-9790 Wortegem-Petegem
Belgium
Tel: 00 32 56 694 200 Fax: 00 32 56 694 249
e-mail: danilith@milbank.co.uk
website: www.milbank.co.uk
Agrément
Certificate
No 04/4119
Designated by Government
to issue
European Technical
Approvals
DANILITH PREFABRICATED BUILDING SYSTEM
Systeme pour constructions
Bausystem
Product
Regulations • THIS CERTIFICATE RELATES
TO THE DANILITH
PREFABRICATED BUILDING
SYSTEM, COMPRISING A
RANGE OF FACTORYFABRICATED
REINFORCED
CONCRETE PANELS.
• The system is for use as:
– a loadbearing external wall,
incorporating a phenolic foam
insulation core, faced externally
with cut half-bricks for use
above the damp-proof course
in dwellings up to two storeys
high, with a room in the roof,
– a loadbearing/nonloadbearing
internal wall,
– a separating wall.
• Installation must be carried
out by contractors approved by
the Certificate holder.
(4-) Nh2
continued
2
Requirement: E1 Protection against sound from other parts of the building and
adjoining buildings
Comment: Constructions incorporating the panels can adequately resist
sound transmission. See section 14 of this Certificate.
Requirement: L1 Dwellings
Comment: Walls will contribute to enabling a building to meet the
elemental Target U value or carbon index method of
demonstrating compliance. See sections 12.1, 12.3, 12.5
and 13 of this Certificate.
Requirement: Regulation 7 Materials and workmanship
Comment: The system is acceptable. See section 17.1 of this Certificate.
2 The Building Standards (Scotland) Regulations 1990 (as amended)
In the opinion of the BBA, the Danilith Prefabricated Building System, if
used in accordance with the provisions of this Certificate, will satisfy or
contribute to satisfying the various Regulations and related Technical
Standards as listed below.
Regulation: 10 Fitness of materials and workmanship
Standard: B2.1 Selection and use of materials, fittings, and components, and
workmanship
Comment: The panels can contribute to a construction meeting this
Standard. See the Installation part of this Certificate.
Standard: B2.2 Selection and use of materials, fittings, and components, and
workmanship
Comment: The panels are acceptable. See section 17.1 of this Certificate.
Regulation: 11 Structure
Standard: C2.1 Stability
Comment: The panels will have sufficient strength and stiffness when
designed in accordance with sections 10.1 and 10.2 of this
Certificate.
Regulation: 12 Structural fire precautions
Standards: D2.1 and D2.2 Structural protection — Principles
Comment: The panels can be used to construct walls with the required
duration of fire resistance. See sections 15.1 to 15.3 of this
Certificate.
Standard: D2.3 Structural protection — Non-combustible materials
Comment: The system can satisfy the exceptions permitted for dwellings.
See sections 15.1 and 15.3 of this Certificate.
Standard: D5.1 Separating walls and separating floors — Principles
Standard: D5.2 Separating walls and separating floors — Buildings of purpose
group 1
Comment: The panels can satisfy these Standards. See section 15.3 of this
Certificate.
Standard: D5.7 Separating walls and separating floors — Non-combustible
materials
Comment: Separating walls incorporating the panels are non-combustible
and can satisfy this Standard.
Standard: D5.9 Separating walls and separating floors — Junctions
Comment: Junctions between separating walls and external walls can
maintain the required level of fire safety performance. See
section 15.3 of this Certificate.
Standard: D7.1 Fire spread on internal linings — Principles
Comment: The panels will adequately resist surface spread of flame over
their surface. See section 15.2 of this Certificate.
Standard: D8.1 Fire spread to adjoining buildings — Principles
Comment: The system uses combustible insulation and therefore cannot
meet Standard D8.1. External walls constructed using the
panels would be classed as an ‘unprotected area’ as defined in
the Technical Standards Part D8.1 note C. However, in the
opinion of the BBA it would not be unreasonable to seek a
relaxation of this Standard.
Standard: D10.1 Fire spread on an external wall
Comment: The external wall panel can satisfy this Standard. See
section 15.2 of this Certificate.
Regulation: 17 Resistance to moisture
Standard: G3.1 Resistance to precipitation – Resistance to precipitation
Comment: The external wall panel can satisfy this Standard. See
sections 9.1, 9.2 and 11.1 of this Certificate.
Regulation: 18 Resistance to condensation
Standard: G4.1 Condensation — Interstitial condensation
Standard: G4.2 Condensation — Surface condensation
Comment: The external wall panel can satisfy these Standards. See
section 11.1 of this Certificate.
Regulation: 19 Resistance to transmission of sound
Standard: H2.1 Walls and floors to resist sound transmission — Airborne
sound
Comment: Separating walls can adequately resist airborne sound
transmission between dwellings. See section 14 of this Certificate.
continued
• It is essential that the product
is used in accordance with the
conditions set out in the Design
Data and Installation sections
of this Certificate.
• This assessment does not
cover foundations, beams,
trusses, lintels, staircases,
windows, doorsets, fittings,
floors, roofs, adequacy of
plumbing, drainage,
ventilation, electrical services,
flues and heat producing
appliances.
• The system can be used to
construct buildings with a
variety of individual treatments
and plan forms.
• Users, when specifying plan
form, internal sub-division,
siting of the building, access
for the disabled, access for fire
services, and means of
(warning and) escape in case
of fire should ensure
compliance with the relevant
Building Regulations’
requirements.
• The system is marketed and
distributed in the UK by
Milbank Industries Ltd,
Earls Colne Business Park,
Earls Colne, Colchester,
Essex CO6 2NS.
Tel: 01787 223931
Fax: 01787 220525.
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Regulation: 22 Conservation of fuel and power
Standard: J3.4 Buildings in purpose group 1 — Target U-value Method
Standard: J3.11 Buildings in purpose group 1 — Carbon index Method
Comment: The external wall panels will contribute to enabling, a building
to satisfy the requirements of these Standards. See
sections 12.1 and 12.3 of this Certificate.
Standard: J4.1 Buildings in purpose group 1 — Limiting thermal bridging
at junctions and around
openings
Standard: J5.1 Buildings in purpose group 1 — Limiting infiltration
Comment: External walls can adequately limit heat loss at junctions and
restrict air leakage. See sections 12.4, 12.5 and 13 of this
Certificate.
3 The Building Regulations (Northern Ireland) 2000
In the opinion of the BBA, the Danilith Prefabricated Building System, if
used in accordance with the provisions of this Certificate, will satisfy or
contribute to satisfying the various Building Regulations as listed below.
Regulation: B2 Fitness of materials and workmanship
Comment: The system is acceptable. See section 17.1 of this Certificate.
Regulation: C4 Resistance to ground moisture and weather
Comment: External walls can satisfy this Regulation. See sections 9.1 and
9.2 of this Certificate.
Regulation: C5 Condensation
Comment: The external wall panel can satisfy this Regulation. See
section 11.1 of this Certificate.
Regulation: D1 Stability
Comment: Walls constructed from the product will have sufficient strength
and stiffness when designed in accordance with sections 10.1
and 10.2 of this Certificate.
Regulation: E3 Internal fire spread — Linings
Comment: The panels will adequately resist spread of flame over their
surface. See section 15.2 of this Certificate.
Regulation: E4 Internal fire spread — Structure
Comment: The panels can satisfy this Regulation. See sections 15.1 and
15.3 of this Certificate.
Regulation: E5 External fire spread
Comment: The external wall panel can satisfy this Regulation. See
sections 15.1 and 15.3 of this Certificate.
Regulation: F2 Building fabric
Comment: External walls will satisfy the requirements for maximum U values
in Table 1.2 of Technical Booklet F. See sections 12.1 to
12.3, 12.5 and 13 of this Certificate.
Regulation: G2 Separating walls and separating floors
Comment: Separating walls can adequately resist airborne sound
transmission between dwellings. See section 14 of this Certificate.
3
4 Construction (Design and Management) Regulations 1994 (as amended)
Construction (Design and Management) Regulations (Northern Ireland)
1995 (as amended)
Information in this Certificate may assist the client, planning supervisor,
designer and contractors to address their obligations under these Regulations.
See sections: 6 Delivery and site handling (6.2 to 6.4) and 18 Installation
—
General (18.5) .
Technical Specification
5 Description
5.1 The Danilith Prefabricated Building System
comprises:
• reinforced concrete panels with an insulating
core of phenolic foam for external walls (see
Figure 1)
• solid reinforced concrete panels for internal and
separating walls.
5.2 The nominal dimensions of the external wall
panels are given in Table 1.
Table 1 Panel characteristics
Panel type
external wall internal wall
Width (m) up to 10 up to 8.5
Height (m) up to 2.82 up to 2.68
Thickness (m) 0.250(1) 0.1–0.15
(1) Other thicknesses are available.
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5.3 The panels are manufactured in an automated
factory process and include cut-outs for openings.
External walls
5.4 The external wall panel consists of:
• 42 mm cut half-bricks comprising either:
– clay bricks of FL quality in accordance with
BS 3921 : 1985 (F2, S2 in accordance with
BS EN 771-2 : 2003)
– calcium silicate bricks with a compressive
strength class of 25 and freeze/thaw
resistance to BS EN 772-18 : 2000
– other types of cut half-bricks are available but
are outside the scope of the Certificate. See
Certificate holder for details
• 58 mm high-density concrete backing to outer
leaf to grade C25/30:2b with a density of
2350 kgm–3 reinforced with corrosion-protected
galvanized steel fibres
• 65 mm rigid phenolic foam thermal insulation
with a density of 38 to 40 kgm–3
• 85 mm concrete grade LC20/25:1 with a density
of 1750 kgm–3, reinforced with a welded mesh
• 10 mm site-applied gypsum plaster
• inner and outer layers are connected by stainless
steel ties at 600 mm centres
• additional reinforcement is provided around
openings and at the top and bottom of panels
as required.
Internal walls
5.5 The internal wall panel consists of:
• 80 mm to 150 mm concrete grade LC20/25:1
with a density of 1750 kgm–3 or 2350 kgm–3
reinforced with a welded mesh and cross beams
• 2 mm thick cement-sand render finish on both sides.
Separating walls
5.6 The separating wall consists of:
• two 100 mm leaves of dense concrete
C25/30:2b with a density of 2350 kgm–3
separated by a cavity of at least 50 mm
5.7 Floors must be designed in accordance with
BS 8110-1 : 1997. See the Certificate holder for
details.
5.8 Fixings used with the panels are:
• anchoring bolts — used to fix cast-in restraint
straps to floors
• weld plates — used to secure wall panels during
construction
• reinforcing rods — used for external wall corner
joints
• cement infill — C20 grade used for filling joints
• mortar — used for bedding and pointing the
wall panels.
5.9 Ancillary items for use with this system include:
• fixing screws
• foam joint sealant.
4
Figure 1 Typical external wall panel
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6 Delivery and site handling
6.1 Wall panels are transported to site on a flat
bed lorry or a trailer long enough to fully-support
the panel. Each panel carries the name of the
manufacturer, the panel identification number and
the BBA logo incorporating the number of this
Certificate.
6.2 The panels cannot be manhandled on site,
and should not be removed from the delivery
vehicle until ready for installation.
6.3 Hard standings must be prepared to allow for
the delivery vehicle and the use of a mobile crane.
Panels must be unloaded with care to avoid
damage.
6.4 Lifting points are cast into each panel. Prior to
unloading, lifting clutches are attached to all lifting
points on the panel. Lifting chains and spreader
beams are used with the lifting clutches to unload
and position the panels.
Design Data
7 General
7.1 The Danilith Prefabricated Building System,
when designed and installed in accordance with
this Certificate and the Certificate holder’s
Installation Procedures, is satisfactory for dwellings
up to two storeys high plus a room in the roof. The
internal wall panels can be used as loadbearing or
non-loadbearing walls.
7.2 The building system must be designed and
constructed in accordance with BS 8110-1 : 1997
and BS 8110-2 : 1985. This design should take
into account, hoisting, wind loadings, stability and
the related exposure conditions (see section 9).
7.3 To achieve adequate stability, the various
elements (floor, external and internal walls, and
roof structure) should be tied together to achieve a
box-like structure. Particular attention should be
made to the recommendations given in section 10.
7.4 All structural design and detailing involving
the use of the product must be carried out in
accordance with UK practice and Statutory Building
Regulations under the direct supervision of Chartered
Structural or Civil Engineers or appropriately
qualified persons with experience of this building
system. Any changes deemed necessary on site
must be agreed with the Certificate holder.
7.5 Where buildings need to meet NHBC
Standards or Zurich Building Guarantees Technical
Standards, specifiers should observe the
requirements of these standards.
8 Practicability of installation
The system is practicable for use in constructing
walls of a building up to two storeys high. All site
erection must be carried out in accordance with the
Certificate holder’s installation instructions and the
Installation part of this Certificate.
9 Weathertightness
9.1 The external wall surfaces will provide
adequate weather resistance. The final
weather resistance of the building is
dependent upon the efficient positioning and
sealing of all joints.
9.2 When the system is used to form an external
masonry wall the outer leaf must be designed and
constructed in accordance with BS 8110-1 :
1997, BS 8110-2 : 1985 and BS 8000-3 :
2001, incorporating the dpc’s position in
accordance with BS 5628-3 : 2001. The
guidance given in section 3 of BRE Digest 262
Thermal insulation : avoiding risks should be
followed with regard to rain penetration in that the
designer selects a construction appropriate to the
local wind-driven rain index, paying due regard to
the design detailing, workmanship and materials to
be used.
10 Structural performance
10.1 Walls constructed using the panels
may be treated as conventional concrete
walls and should be designed and
constructed in accordance with the
recommendations of BS 8110-1 : 1997 and
BS 8110-2 : 1985.
10.2 For external walls, the nominal concrete
cover to reinforcement is that appropriate to ‘mild’
exposure in accordance with BS 8110-1 : 1997
Tables 3.2 and 3.4 and the requirements for fire
resistance in accordance with BS 8110-2 : 1985,
section 4.
10.3 Reinforcement and framing around openings,
form an integral part of the wall. Where heavier
loads are being supported or large span openings
are required, the specification and design must be
determined by the Engineer or appropriately
qualified person responsible for the stability of the
building (see also section 17.2).
10.4 The strength of all connection details which
tie walls, comprising the product, to other structural
elements (such as floors, roofs) must be evaluated
and provide adequate stability for the overall
building design. The specification and design for
these items must be determined by the Engineer or
appropriately qualified person responsible for the
stability of the building. Guidance on the design of
connection details may be obtained from the
Certificate holder.
10.5 When constructed in accordance with the
Certificate holder’s Installation Procedures the
completed structure behaves in the same way as
traditional masonry construction and adequately
resists the effects of wind and combined bending
and axial loads.
5
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11 Condensation
11.1 Provided the panels are correctly
sealed to each other, the risk of surface and
interstitial condensation under normal
domestic use will be minimal. (See also
section 12.5).
11.2 The risk of interstitial condensation in both the
external walling and the roofing is greatest when the
building is drying out after construction. Guidance on
preventing condensation is given in BRE Digest 369
Interstitial condensation and fabric degradation
and BRE Digest 262 Thermal insulation : avoiding
risks.
11.3 Buildings constructed using the wall panels
are suitable for use where provision has been
made for rapid and background ventilation in
accordance with the statutory Building Regulations.
12 Thermal properties
12.1 Typical external wall constructions will
contribute to achieving compliance using the
Target U-value Method, Carbon Index
Method or Carbon Emissions Calculation Method.
12.2 The U value of the external wall
panels do not exceed the maximum values in
the Elemental Approach given in Technical
Booklet F, Table 1.2.
12.3 When modelled in accordance with
BS EN 10211 : 1996 the estimated
U value of the external wall did not exceed
0.40 Wm–2K–1.
12.4 The thermal insulation is carried
through into the joints and junctions between
external wall panels and therefore, will
adequately limit heat loss.
12.5 The wall panels can adequately limit
heat loss and surface condensation risk at
junctions and around openings when
detailed in accordance with the relevant design
guidance in the Robust details publication Limiting
thermal bridging and air leakage : Robust
construction details for dwellings and similar
buildings TSO 2002.
13 Air leakage
When the external wall panel joints and
junctions with other elements are properly
sealed the wall will adequately limit
unwanted air infiltration.
14 Acoustic properties
Separating walls as described in section 5.6
with panel joints and junctions correctly
sealed, will provide satisfactory airborne
sound insulation and are comparable to:
England and Wales
Approved Document E, Section 2, wall type 2
Scotland
Technical Standards (H2.1 to H2.3), wall type 2
Northern Ireland
Technical Booklet G, paragraph 1.6, wall type 2.
15 Behaviour in relation to fire
15.1 The use of the system will not
introduce any additional hazard in respect of
behaviour in fire when compared with a
system using traditional masonry constructions.
15.2 The internal and external wall, and floor
panel surfaces are classified class 0 or ‘low risk’ as
defined in the national Building Regulations thus:
England and Wales
Approved Document B, paragraph A12
Scotland
Technical Standards (D1.3), Table 3
Northern Ireland
Technical Booklet E, Section 2.4.
15.3 When assessed in accordance with
BS 8110-2 : 1985 the panels achieved the fire
resistance requirements given in Table 2.
Table 2 Minimum fire resistance requirements
Construction Description Result
type (min)
Separating wall 2 x 100 mm leaves of high- 60
density concrete (2350 kgm–3)
separated by a cavity
External wall 42 mm cut half-brick, 30
58 mm high-density concrete,
65 mm phenolic foam insulation,
85 mm lightweight concrete,
10 mm gypsum plaster
Typical 50 mm high-density concrete, 30
intermediate (2350 kgm–3) covered
floor by structural concrete
15.4 When any other form of wall construction
incorporating the system is subject to fire
resistance requirements, an appropriate
assessment or test must be carried out by a
UKAS (United Kingdom Accreditation Service)
approved testing laboratory.
15.5 Constructions incorporating the product
must include suitable provision for cavity barriers
and for fire stopping at junctions with other
elements in accordance with the requirements of
the national Building Regulations.
16 Proximity of flues and appliances
When installing certain flue pipes and/or heat
producing appliances into the system, the relevant
provisions of the national Building Regulations are
applicable:
England and Wales
Approved Document J
6
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Scotland
Technical Standards, Part F. Provisions deemed to
satisfy the standards
Northern Ireland
Technical Booklet L.
17 Durability
17.1 Walls comprising the Danilith
Prefabricated Building System and
approved jointing materials will retain their
strength and insulating properties for a service life
at least equivalent to that for brick-and-block
masonry.
17.2 Building systems constructed with the system
must be maintained in accordance with BS 8210 :
1986 with particular attention to the guidance
given in Appendix A1.
Installation
18 General
18.1 The installation of the Danilith Prefabricated
Building System must comply with the details given
in the Certificate holder’s Installation manual and
the provisions of this Certificate (see Figures 2
and 3).
18.2 The main contractor must ensure the
foundations are correct and that the accuracy of
all foundations, plinths, substructure masonry,
concrete is in accordance with the Certificate
holder’s instructions.
18.3 To achieve a structurally-stable construction,
sufficiently plane for finishes, props must be used
to brace the wall panels during construction. Castin
weld plates are secured with cover plates fixed
in accordance with the Certificate holder’s
installation instructions with a 4 mm fillet weld to
the internal leaf of the external wall. These are
used to achieve stability during the construction
phase. The infill concrete and the interlinking
reinforcement provide the permanent stability to
the completed structure.
18.4 Electrical and plumbing services are
outside the scope of this Certificate. However,
in designing and installing these services,
precautions must be taken to avoid the possible
risk of long-term damage to the structure or the
services by such actions as the ingress of water,
water vapour, or condensation from cold water
service pipes. Electrical ducting and chasing for
plumbing are incorporated into the building system.
18.5 When installing intermediate floor units,
precautions, eg passive fall arrest and perimeter
protection systems, must be used. Advice from the
Certificate holder should be sought.
19 Procedure
19.1 A suitable damp-proof course must be used
with the building system and must be installed in
accordance with the Certificate holder’s instructions.
Ground floor — walls
19.2 A survey is conducted prior to the installation
of the wall panel to check for any excessive variation
between levels. Shims are placed as required to
ensure the walls are level. It is important that the
wall panels are correctly aligned.
19.3 During installation the wall panel is
lowered onto a thick mortar bed and held in place
with a prop.
19.4 The wall panel remains supported by the
lifting gear until the supporting prop is in place.
Panels must be supported by at least one prop,
however, longer panels may require additional
propping.
19.5 The wall panels are secured by fixing the tie
bars that are cast into the bottom of each wall
panel (see Figure 3). The panels are secured
together by cast-in weld plates as described in
section 18.3.
19.6 Corner external wall panels have a 45°
mitred edge and steel ‘U’ bars projecting from the
inner concrete leaf. Panels are abutted to enable a
vertical mortar joint on the outer face. Reinforcing
steel rods are threaded through the protecting
‘U’ bars from above and an aluminium angle is
fitted to the inside of the internal corner. The inner
leaf of the joint is filled with foam insulation and
cement. The aluminium angle profile holds the infill
in place and acts as a temporary shutter whilst the
cement cures.
19.7 Internal walls are installed using a similar
procedure as external wall panels. Once in place
internal walls are connected together and connected
to external walls using drilled and plug joints and
frame anchors.
Intermediate floors
19.8 The intermediate floor is supported by the
loadbearing interior wall panels and the inner leaf
of the exterior wall panels.
19.9 The internal walls are secured to the
intermediate floor by brackets fitted into the lifting
eyes cast into the wall panels during manufacture.
19.10 The upper wall unit must be in place before
the concrete compression slab is applied. The wall
panels incorporate projecting reinforcement or
restraint straps that are cast into the floor.
19.11 Wall panels on the upper floor are
installed in the same manner as the ground-floor
panels (see sections 19.3 to 19.7), however, the
lifting points on the top of the lower panel must be
filled with mortar and covered with a damp-proof
membrane to prevent the ingress of water.
7
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Figure 2 Wall panel connection
panel joint
pointed up
injected polyurethane foam
80 100 4 mm
cast-in mild steel plate
weld plates covered
with plaster
tie reinforcement
welded to plate
150 100 4 mm
mild steel cover plate welded
to cast-in plates
cross-section of vertical junction
panel joint
pointed up
10 mm anchor bar
8 mm U bars
plan cross-section of corner junction
injected
polyurethane
foam
cement infill
side cross-section of horizontal junction
mortar bed
between wall panels
weld plates covered
with plaster
80 100 4 mm
cast-in mild steel plate
150 100 4 mm
mild steel cover plate
welded to cast-in plates
