Assessing Greencore's innovative modern method of construction

Greencore has developed an innovative modern methods of construction (MMC) using a closed timber framed panel manufactured off-site and insulated with natural materials such as hemp-lime and wood-fibre. This allows it to build homes that are not only high quality and energy-efficient, but which also lock up more carbon than they emit during construction and also over their lifetimes. The construction system, called Biond, could help the housebuilding sector transform its methods to meet the UK’s net zero targets and enable people to reduce their heating bills.

Having proved its concept, Greencore sought an investment from M&G that would enable it to scale production with a new manufacturing facility. We acted as independent reviewers, carrying out due diligence on information Greencore provided to M&G to secure investment.

This included a whole life embodied carbon assessment on a completed Greencore home that compared it to a traditionally constructed house. The Greencore home takes advantage of the sequestered carbon stored in the cross laminated timber (CLT) flooring and the Biond panel incorporating natural fibre insulation. As a result, we found it achieved an A++ rating with a whole-life embodied carbon total of -278kgCO₂e/m2 compared with the Royal Institute of British Architects’ 2030 target of +625 kgCO₂e/m2 for housing.

Outperforming competitors

Our structural review of the Biond panel found that it has a good load-bearing capacity, which could be increased further to make it suitable for taller residential apartment developments (up to 18m). With its unique insulation and its UK Government classification as a category two form of MMC – and hence a go-to product for housebuilders – we concluded that the Biond panel has a clear advantage over its competitors.

A review of façade performance for Biond evaluated it against five UK and six international competitors. We considered properties such as dimensions, thermal performance, air tightness, fire resistance, acoustics, and sustainability – checking Greencore’s product against the stringent Passivhaus requirements. We found that the system outperformed competitors on envelope airtightness and in the sustainability of its insulating materials, while matching them in other key criteria.

Future-proof construction

To assess energy performance, we assessed three completed Greencore properties using the Standard Assessment Procedure (SAP) methodology. We found that all the homes performed well compared to current and future building regulations as well as LETI and Passivhaus targets. Passive design principles reduce energy use while the highly efficient building fabric exceeds future building regulations. High-performing MEP systems exceed current targets and make use of the best available controls.

With our technical expertise and experience of delivering MMC confirming the potential of houses built with the Biond panel, M&G’s investment will help Greencore transform the way homes are built in the UK.