Aviva Studios, Manchester
Date completed - September 2023 | Construction value - £9.1m | Main contractor - Laing O'Rourke
Mansell Building Solutions has completed its part in the construction of Factory International, a multi-use arts and entertainment complex in the heart of Manchester’s urban hub of Spinningfields.
A new jewel in Manchester’s crown
The Factory International, a cutting-edge multi-purpose building showcasing the most avant-garde music, drama and art, was constructed in Manchester on the former site of Granada Studios. Commissioned by the Manchester City Council and the Arts Council England, the new facility houses intimate works across various art forms, major exhibitions, and concerts.
A true landmark for not just the North West, but the UK, the Factory International has been long in the making and will stand tall amongst Manchester’s most valued cultural attractions.
From a construction point of view, it was designed to be flexible enough to host simultaneous events in the warehouse and auditorium, as well as to combine both spaces for different types of events. The warehouse can accommodate up to 5,000 visitors and can be divided into two smaller spaces with moveable acoustic walls, while the auditorium seats up to 1,600 people.
Scope of Work
We were awarded the contract to supply and install partitions, ceilings, SFS systems, acoustic linings, and plastering for this ground-breaking, architecturally unique public space. The work we did would unlock the potential of the site, enabling the multi-purpose space to host different events in its different spaces while remaining soundproof from each other - a vital feature of the venue.
While the works we carried out were extensive, perhaps the most challenging aspect of the project was the provision of high-quality, cutting-edge acoustic insulation panels, Knauf Partition and ceiling systems.
Challenges Encountered – The Mega Walls
The design of the site featured a box within a box structure where the inner auditorium and event space was encased in a larger shell or ‘box’. In between these two box structures we had to work within a 2.4-metre span.
The application of drywalling, SFS and acoustic insulation to the inner wall of the box within a box presented several challenges, particularly at the upper levels where the roof reached as high as 28 metres. Working within such a confined space made it difficult to transport and position the necessary equipment and materials.
One significant challenge was fixing insulation slabs, or acoustic baffles, to the inside of the outer wall to absorb any sound. Moreover, partition and SFS walls had to be built within the cavity for fire safety and acoustic purposes, further complicating the logistics of working in such a tight space.
Solutions Implemented
To overcome the challenges posed by the box-within-a-box construction, we employed a combination of smart planning, innovative design, and flexibility. The project manager worked closely with the architect from the earliest design stages, advising on the buildability of the structure and ensuring the appropriate plans were in place for each design element. This collaboration continued throughout the project with weekly and sometimes daily design meetings to keep the project on track and confirm that everything was being executed as planned.
When it came to working within the tight 2.4m span between the structures, Mansell used tube and fitting scaffolding extensively to reach the areas of the confined site. Additionally, a small winch was designed and used to transport materials up to the necessary height. Though this approach was time-consuming, it enabled the team to complete the required insulation work safely and effectively.
Challenges Encountered – The Ground Floor Foyer Ceiling
This involved acoustic detailing to prevent sound from travelling from the performance spaces above.
Due to the loadings of the Mechanical and Electrical equipment that was to be fixed to the ceiling, the ceiling design was changed from a light gauge Knauf frame ceiling to a heavy gauge steel Metsec SFS frame system. This was then insulated within the cavity of the Metsec SFS and boarded with three layers of Knauf high-performance acoustic board.
Mansell installed unistrut supports to the underside of the Metsec SFS system, providing a fixing system to support the mechanical and electrical equipment.
A secondary, decorative Knauf Heraklith board was then finally fixed to the underside of the Metsec ceiling to provide an attractive finish.
Solutions Implemented
Mansell worked closely with the design team, Kauf dry lining and Metsec at the earliest design stages, advising on the buildability of the ceiling and ensuring the appropriate plans were in place for each design element.
Conclusion
It goes without saying that this was a project we were extremely proud to be a part of. Manchester is a wonderful city ripe with culture, the arts and entertainment and the Factory International is undoubtedly a very significant step for the city's bustling entertainment scene. Having already hosted the 2023 International Festival, the future is indeed bright for the venue and the city.
The work we did showcased our commitment to working with clients from the earliest design stages, ensuring projects are highly buildable and completed to a high standard without costly and time-consuming delays. By combining meticulous planning, innovative construction solutions, and flexibility, We were able to successfully install the acoustic insulation, Partitions, ceilings and SFS systems, ultimately enhancing the venue's versatility and providing optimal conditions for various artistic performances and events.
