Donaldson Timber Systems

Leading UK offsite frame manufacturer, Donaldson Timber Systems (DTS), has become the first timber frame manufacturer to offer a published, third party accredited environmental product declaration (EPD) for its product, proving its sustainability credentials.

As part of a process to cover the full DTS product range, the DTS Alpha system is the first off-site assembled timber frame wall panel in the UK to offer an approved EPD.

The EPD, which transparently communicates the environmental performance of a product over its lifetime, demonstrates the benefits building with timber can bring. The Global Warming Potential (GWP) of Alpha is a carbon positive, –1.53kg CO2e, meaning that 1.53kg of carbon is stored in every m² of Alpha external wall. For a typical four bed detached home built using Alpha, 250kg of carbon is stored in the timber frame elements of the external walls alone, not including the timber floors and roof trusses.

This product life-cycle assessment supports carbon emission reduction by making it possible to compare the impacts of different materials and products accurately, allowing customers to select the most sustainable option. In comparison to the Alpha wall panel, according to the EPD produced by the Concrete Block Association (CBA), the cradle-to-grave GWP impact of 1m ² of aggregate concrete blocks is 10.6 kg CO2e. So, for the same standard four bed detached home, 4000kg of carbon is released into the atmosphere.

Based on these figures, if the UK were to build the new Government target of 300,000 homes per year in timber frame as opposed to concrete, it would reduce annual carbon emissions by over one million metric tonnes – the equivalent of the fossil fuel generated electricity needed to run 500,000 homes for a year.

Valid for five years, the EPD is based on current available and published data for end-of-life assumptions. With advances in the industry over the next five years, along with improved building recycling processes and ongoing DTS investments – such as the recent PV panel installation in the factory at Witney – it is expected that performance will be even higher at the next review.

Alpha is the first of 16 base EPDs being worked on by DTS, covering the full product range of floor, wall and roof systems.

Open Panel timber frame is currently the most common timber frame build system in the UK, providing the structural inner leaf walls for buildings using a timber studwork factory formed into panels with structural sheathing and exterior breather membrane.

The DTS Alpha system is a cost-effective solution, offering an efficient and effective build method. Fully tested and technically supported and having been used for 50 years in the UK, this build system is often chosen by clients for their first project utilising an offsite build method.

John Smith, Technical Director at Donaldson Timber Systems, explains:

“The only way to achieve the UK target to be zero-carbon by 2050 is to firstly measure, and then reduce the whole-life carbon of buildings, from cradle to grave. The availability of EPDs is an important step in recognising this. Without measuring and reducing embodied carbon, there is a very real risk that the new buildings constructed to new standards in 2026 and beyond won’t achieve true zero carbon, as the embodied carbon in the fabric will never be offset by using even the greenest energy to run the home. This is something we feel strongly about, and one of the reasons we’re investing in this process for all DTS products.”

Alex Goodfellow, CEO of Donaldson Offsite added:

“We always champion the use of offsite timber frame construction as the best way to achieve sustainable building practices and meet net zero targets, so it’s fantastic to have a verified EPD to prove these claims. We’re seeing increasing numbers of customers asking for EPDs, as they look to meet carbon goals, and need to be able to prove that the products they specify are making a difference.

“We’re proud to be leading the industry with proof that timber frame is a carbon sink, and we’re already working on improvements to show further benefits when we review the EPD in five years’ time.”

As part of the Donaldson Group’s Offsite division, DTS prides itself on being highly sustainable, innovative and efficient. With unrivalled experience and knowledge in offsite construction, DTS has an established history of bringing new commercial and operational innovations to the market.

 Leading UK offsite timber frame manufacturer, Donaldson Timber Systems (DTS), has increased capacity and boosted technical capabilities at its Oxfordshire factory, following an investment of more than £10m.

The investment in machinery and performance upgrades at the Witney site includes four state of the art timber processing centres and a new floor panel production line offering customers a fully completed pre-glued floor cassette solution. The site has also installed the most advanced automated pre-insulated closed panel wall production line in Europe.

The purpose of the machinery investments is to increase automation to improve efficiency and create additional capacity, which in turn reduces the manual labour required and makes operative positions more inclusive. The acquisition of new technology also increases the factory’s technical capabilities so more advanced products for MMC, like DTS’ Sigma II timber frame system, can be manufactured with the quality assurance the industry demands.

Some of the pieces of technology were created specifically for DTS and have never been used before in the industry. Partnering with Randek on much of the machinery development, new techniques, and innovations, DTS ensured current and advanced elements of technology were used, including robotics and laser integration. The increased automation also reduces the requirements for paper drawings as plans are input digitally, further reducing carbon footprint.

Photovoltaic (PV) cells, or solar panels, have been installed on the factory roof and will produce just under one megawatt of electricity, covering the factory’s own energy needs and an excess of green energy that is exported back into the national grid for other local businesses and homes to use. This significantly reduces the site’s environmental footprint and combined with new electric vehicle charging points for staff and visitors, supports DTS’ sustainability goals.

Frank O’Reilly, Manufacturing Director at DTS, said: “The installation of this new machinery in a working factory is unusual for the industry and the process required a phenomenal amount of logistical planning over a period of a couple of years. We’re all really proud of the results. We’re creating the capacity and technical capabilities customers require to continue building more advanced and energy-efficient homes and buildings – and futureproofing our own business in the process.

“We’re also excited about what this means for our colleagues, as it is revolutionising the operations process. Now a less physically demanding role, we can hire a wider variety of people to work on site, helping to plug the current skills gap in construction. We’ve also hired people with an automation background from the automotive and engineering sectors to ensure we upskill our teams and are making the best use of our new capabilities. These efficiencies also provide an opportunity to increase production, creating more positions in time, and allowing us to redeploy people to more value-added roles.”

Rod Allan, Managing Director of DTS, said: “Timber is the only truly sustainable building material and we are well-respected in the industry for the quality of our products. But rather than rest on our laurels, we continue to look forward and innovate. We have created the scope to add more capacity and capabilities to the factory over time without the need for a large-scale overhaul like this one, and we have created a platform for more R&D. It has also made positive changes to our colleagues, as we have seen more people switch to electric vehicles thanks to the free charging points on site. This is a significant investment but one that will set us and our customers up for continued success in reducing carbon for years to come.”

Ola Lindh, Randek CEO, said: “Partnerships and collaborations lie at the heart of our mission at Randek. Prefabrication isn’t just about constructing buildings; it’s about co-creating solutions with our customers, refining their processes, and integrating our technology to drive efficiency and automation. This synergy not only makes housing more affordable but also paves the way for a sustainable future.”

Currently led by the sixth generation of Donaldson, the 163-year-old Donaldson Group comprises a total of 17 specialist timber and building product businesses and brands, operating throughout the UK from 45 locations and employing over 1,500 people. The businesses that make up the Group trade and operate independently, sharing best practice, innovation, purchasing synergies, and market analysis.

Donaldson Timber Systems (DTS) was proud to support a recent visit from members of the House of Lords’ Built Environment Committee as part of its inquiry into the future of modern methods of construction (MMC).

Chair of the Lords Select Committee, Lord Moylan, along with Lord Best, Baroness Eaton, Lord Faulkner of Worcester, Earl Russell, and Baroness Thornhill, first visited West Herts College’s, Hemel Hempstead campus to learn more about the apprenticeship programme offered in partnership with DTS.

As announced earlier this year, the 2.5-year programme, open to students on the College’s Level 2 City and Guilds carpentry course, comprises four days per week working on-site, and one day per week attending the College. The in-class modules include an additional module that will focus on MMC for offsite manufactured timber frame, which was developed in partnership with DTS. This covers an understanding of construction technology; health and safety; an introduction to MMC and offsite timber frame build systems; together with understanding construction information, materials, and the installation process, including site project communications.

The Committee then travelled to Spencer’s Park in Hemel Hempstead, a Countryside Partnerships development, to see first-hand MMC actually taking place on site. The 600-plot development has built its houses using DTS’ Sigma II closed panel timber frame system.

The award-winning, BOPAS+ accredited and BBA Certified build system, is designed to achieve superior levels of external wall performance, suitable for projects seeking to attain the very highest fabric efficiency standards. With excellent thermal properties and air-tightness, the Sigma® II Build System offers reduced on-site material and labour costs, by using conventional materials in a more effective manner.

Simon Horn, Technical Development Manager at DTS, said: “The visit from members of the Lords Select Committee was an extremely valuable opportunity to demonstrate our commitment to the future of MMC and the wider timber frame industry, through our partnership with West Herts College, as well as showcase the benefits of MMC on a live site at Countryside Partnerships, Spencer’s Park, Hemel Hempstead.”

“Although the Committee’s inquiry is investigating some of the recent challenges the industry has faced with MMC and Cat 1 Volumetric build systems, we were proud to show them our success and the importance of investing in established, sustainable technologies, for Cat 2 Panelised build systems and in training the next generation. We thank the members of the Committee for their time.”

Gill Worgan, Principal and CEO at West Herts College said: “We were delighted to welcome members of the House of Lords Built Environment Committee and colleagues from Donaldson Timber Systems to our Construction and Engineering Centre at our Hemel Hempstead campus.

“The visit provided a valuable platform for discussions surrounding the evolution of construction skills and the pivotal role modern methods of construction play in shaping the industry’s future.
At West Herts College we’re working closely with employers such as Donaldson Timber Systems to ensure that our students are equipped with the modern skills required to step into careers in the construction sector.”

Offsite Expo 2022, taking place from 20^th-21^st September at Coventry Building Society Arena, brings together those who are driving change in the construction sector, and we are delighted to confirm that we will be exhibiting at stand E10 for the duration of the show.

And not only that, but our very own Technical Director, John Smith, will be speaking in the ‘Explore Offsite’ at Offsite Expo Masterclasses on 21st September at 12:10 – 13:30 as part of the Structural Timber session. John will be focussing the discussion on the Journey to the Future Homes Standard, which aims to reduce energy usage and greenhouse emissions of new buildings. A prominent topic in the housebuilding industry at the moment.

The event will play host to the leading UK and international offsite manufacturers and component suppliers over two days showcasing a broad spectrum of panelised, volumetric modular solutions, pod and prefabricated MEP solutions, as well as the latest in Digital and BIM technology.

Throughout the two days, the show will welcome over 4,000 visitors, host over 100 exhibition stands, hear from 100 speakers and facilitate over 300 meetings in the buyers and specifiers lounge.

You can visit us at stand E10 where we will be showcasing our leading timber frame systems, and our expert team will be on hand to answer any questions you may have.

Gemma Darroch, Key Account Manager at Donaldson Timber Systems, chats to George Sell, at Showhouse Magazine to discuss bringing the latest residential MMC techniques to the public sector.

Her career in the construction industry started with a timber-based residential volumetric manufacturer and gave her a solid grounding in the sector. “As it was a start-up in the modular industry, I had the opportunity to oversee the whole process. From laying down the chalk lines on the empty factory floor, to specifying the interior of the very first show house to come off the factory line,” says Darroch.

“I then moved on to a well-established, steel-based cross sector volumetric manufacturer, and after a short time with the company I decided to go freelance until I found the right role that was a good fit for me and matched my values. My goal was to find a socially responsible and sustainable business that truly wanted to make a difference in how we build homes. I joined Donaldson Timber Systems (DTS), formally Stewart Milne Timber Systems, in 2021,” she says.

“DTS is the leading offsite timber systems manufacturer, specialising in the supply and construction of sustainable, state-of-the-art open and closed panel offsite timber frames. I found the company’s approach to people, place and product aligned with my own values on helping to combat the housing crisis we face, through partnerships, knowledge sharing and collaboration – all the while reflecting the government’s construction playbook in involving the supply chain early in the project lifecycle to reduce downstream issues and help deliver clear, outcome-focused designs and specifications.”

“We believe that the three-fold benefits of using offsite timber frame – low energy demand, carbon-neutral raw material, and a proven, reliable, cost-effective mainstream way of building high quality energy efficient homes – are vital to creating sustainable, resilient, and affordable developments for the future,” Darroch adds.

“The company has a long history in the housebuilding sector, delivering more than 150,000 homes since inception, and with a capacity to build 10,000 homes per year across the UK. It works with some of the UK’s largest housebuilders, such as Taylor Wimpey and Barratt Homes.”

Darroch’s focus is on the public sector. She says: “In recent times, we have developed strong collaborative relationships in the affordable housing sector, working with housing associations such as L&Q, Clarion, Orbit and Sanctuary. We recognise the need for the public sector to work collaboratively with the supply chain, ensuring early engagement to ensure value for money every step of the way. Early engagement allows for standardisation and the use of Design for Manufacture and Assembly (DfMA) to take full effect and essentially provide value engineering early on.”

“I have been brought in by the company to build on the company’s existing relationships with a particular focus on the north. We launched our Levelling up the North with MMC campaign back in February, which saw us take the northern affordable housing providers on a journey of discovery from concept to completion of our offsite panelised systems offering, kicking off with a webinar and then following up with site and factory visits. This was designed to show – rather than tell – the story of offsite. I feel this gives the ability to make informed choices when exploring offsite solutions through knowledge sharing. This in turn provides an understanding of what is needed to see the full benefits of offsite.”

The sustainability agenda is a high priority for every element of the new homes supply chain, and DTS is no different. Darroch says: “Environmentally speaking, timber is a natural, renewable material with significant thermal efficiency that helps to lower energy bills for social tenants whilst helping to ensure low-carbon compliance for the housing provider. Fundamentally, for UK housing associations and affordable housing developers, we believe that a timber frame, fabric-first approach to homes must now be considered the go-to solution of choice.”

“In recent times, I have seen the shift in modern methods of construction moving towards panelised systems of CAT2 of the MMC definition framework. While there’s not really a ‘one size fits all’ solution, there is a definite move towards a more flexible way of building while still utilising the benefits of offsite manufacturing. The recently launched Building Better DPS from the National Housing Federation is testament to the shift, as affordable housing providers seek to broaden their range of modern methods of construction,” she adds.

Darroch believes Imminent legislative changes have only strengthened DTS’ position: “The government’s recent announcement of the overhaul of The Procurement Bill will look to establish a single digital platform for supplier registration and set out objectives for public procurement. These include delivering value for money, maximising public benefit, treating suppliers equally and acting with integrity. There is also a strong emphasis on delivering social value.”

“The benefits of using our open and closed panelised systems – Alpha, Delta or Sigma ll – mean that works can still be carried out on site, ensuring that social value potential is reached within the communities served. Our network of subcontractor installers are typically employed in their own regions, and around 90 per cent of their work comes from us, meaning we have a national reach of social value impact – coupled with our national network of factories across the country from the merger with the Donaldson Group of companies.”

“With the government’s forthcoming changes in regulation – an uplift to standards of Part L of the Building Regulations and changes to Part F – which are the first step in achieving the Future Homes Standards, there has never been a more important time for affordable providers to make the switch to offsite construction to achieve the standards required. The Future Homes Standard will require new-build homes to be future-proofed with low carbon heating and world-leading levels of energy efficiency. It will be introduced by 2025, and already our Sigma II closed panel system achieves these standards. That being said, we are constantly evolving and improving our offering through research and development,” concludes Darroch.

Leading UK timber frame manufacturer, Donaldson Timber Systems (DTS) has become one of the first manufacturers to achieve Buildoffsite Property Assurance Scheme Plus (BOPAS plus), a durability assessment for advanced, offsite build systems.

Building on the original BOPAS scheme, BOPAS plus has been developed to introduce a greater focus on the preparedness of the offsite sector to drive digitisation and collaboration in the construction industry.

Donaldson Timber Systems is one of only three businesses in the UK to hold the new accreditation. The DTS Sigma® II system, was one of the first offsite build systems originally to be accredited by BOPAS in 2013.

BOPAS is the industry benchmark to demonstrate quality and durability to funders, lenders, valuers and purchasers, giving them the confidence that homes built using offsite construction will have a life of at least 60 years.

The accreditation process involves a rigorous assessment, including a two-stage review; a detailed interview with Lloyds Register and a full day audit, where the business is required to provide tangible evidence on the plans in place to deliver on its five-year plan.

Rod Allan, Managing Director, Donaldson Timber Systems said: “BOPAS plus is a fantastic achievement for the business, and will help to ensure that we have a clear differentiator when promoting our Sigma® II build system to the market.

“An increased use of our Sigma® II system will reduce the energy required by customers to run their homes, as well as very low embodied carbon from the construction of the home. BOPAS plus will help to provide our clients and the industry with the confidence that our system has been thoroughly assessed and is highly durable.”

Andrew Donaldson, CEO of the Donaldson Group added: “We expect to see a much greater uptake in modern methods of construction in the coming years and anticipate the demand for offsite construction will continue to increase to help address the housing crisis and the drive for net zero. This accreditation further demonstrates the integrity of the offsite method and its longevity. It’s not just a positive for Donaldson Timber Systems and the wider Donaldson Group, but for the offsite sector as a whole.”

BOPAS is recognised by the principal mortgage lenders as providing the necessary assurance underpinned by a warranty provision, that the property will be readily mortgageable for at least 60 years.

We are delighted to announce that Donaldson Timber Systems has achieved the 2022 OUTSTANDING AWARD for customer satisfaction.  This has been awarded to us by In-House Research Ltd, our survey partner, who work with many of the national housebuilders in capturing feedback from customers.

The Outstanding Award is accredited to companies that achieved a Net Promoter Score of 70 or above, based on feedback from customers during 2021.  In-House Research have advised that this award recognises ‘the very best in the industry with world leading customer service and a brand enhancing NPS position’.

Donaldson Timber Systems achieved an NPS of 76.9.