STEEL AND GLASS

STEEL AND GLASS

EFTCG FACADE is a specialist division of SEMS METAL
 

CORE BUSINESS
Our operation specializes in complex steel, membrane and glass structures where we provide a full design, supply and installation service. This strenghtens the existing portfolio of services of the EFTCG Facades Group.

SERVICE
LSG is a client orientated business. We understand and are committed to the need of close client relations which we know is crucial to ensure a successful project execution. LSG needs to remain flexible in our approach, we listen to clients' needs and present solutions suited to them.

QUALITY AND TRAINING
Our Head Engineering office is located in Wuerzburg/Dettelbach, Germany. All of our employees are required to have sound engineering knowledge. We fully support training and development particularly in young people where we participate in the German apprenticeship scheme.

3-DIMENSIONAL FREE FORMS

These structures are commonly known as Grid Shell Structures. The Geometry is a ‘Free Form’ shape and needs to be curved in order to provide inherent stiffness. The steel structure can be made using single elements, with bolted nodes, or can be welded in ladder segments.

HOTEL ART ROTANA | MANAMA, KINGDOM OF BAHRAIN
 

The Five-Star ART Rotana Hotel is located on Amwaj Island, a reclaimed island to the North of Manama. Each room faces the sea. EFTCG scope: Canopy (1,650 m²): Existing of a single layer freeform steel structure of RHS tubes and solid steel nodes. Supported by 3.5 cones (bottom dia. approx. 2m), a lobe and a couple of wall supports at hotel building. Cladded with a mix of insulated aluminium and glass panels above lobby area and non-insulated aluminium and glass panels for outside lobby area. Facade (520 m²): Forming a 10m high curved entrance lobby underneath canopy lobe. Insulated glass panels (1.8m x 2.6m) supported by main mullions and horizontal bracings. Architectural mullions installed for visual effects. 

IZMIR AIRPORT | IZMIR, TURKEY
 

Four Funnel Structures, called "Elephant feet" by our client TAV International from Turkey, are designed with pipe elements. Pipe cross-section selection is an architectural decision as well as the choice of pipe cross-sections provide the structural rigidity which limits horizontal displacements under seismic loads. Full penetration welding is used at nodes located at half length of the elephant feet from the bottom. Site welding is kept at minimum by pre-production of the several separate parts between each node level before installation at the factory. Following completion of welding works, intumescent fire proofing application done on site. Interior glazing system designed with mechanical glass fixing only from top and bottom edges, with fixings connected to the horizontal steel ring element. After completion of the glass installation, the top of the funnel structures (Elephant Feet) is closed with a membrane roof to provide protection against rain and sun but the top connection between membrane structure and main roof of the terminal left open to provide natural air ventilation inside the structure. 

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SPACE FRAME STRUCTURES

Space Frames are amongst the most weight efficient form of light weight steel structures. Elements and nodes are separated and bolted together to form frames. Geometrical shapes can be either curved or flat, with many variations on grid types.

 
CABLE STIFFENED STRUCTURES

High strength cables in stainless steel or galfan coated steel are used to create super transparent structures. The cables are usually prestressed on site in order to increase the rigidity in the overall structure.  

FOUR SEASONS HOTEL | MANAMA, KINGDOM OF BAHRAIN
 

EFTCG Scope of the Five Star Four Seasons Hotel Tower with an overall height of 201m located on reclaimed island in Bahrain Bay, Manama, Kingdom of Bahrain. Scope: Roof substructure (1.960m²) for lobby area: existing of space frame canopy out of CHS tubes and standard nodes. Two conventional main trusses implemented into the space frame structure serving as supports for North and South facade cable net system. Cable Net Wall System (630m²): vertical and horizontal stainless steel cables forming a 1,5m x 1,5m cable mesh to support insulated glass panels by use of cable clamps at South and North facade. Each facade is approx. 12m high and 30m wide. Vestibule: Located in the North Facade forming the main entrance by one exterior and one interior independent facade (6m high and 18m wide). Main entrance via one revolving door and four swing doors.  

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TENSILE STRUCTURES

Tensile or Membrane Structures rely on the integral strength of the covering membrane, covering the supporting steel structure. This can be a woven fabric i.e. PTFE Coated Glass Fibre Fabric, or PVC coated Polyester Fabric. Also available is ETFE which is similar to a PTFE material which is not woven. ETFE can be used in a single layer covering or more commonly in cushions filled with air.

HAZZA BIN ZAYED STADIUM | AL AIN, UAE
 

The Hazza Bin Zayed Stadium represents Phase 1 of a mixed use development comprising the sports stadium, a commercial office building, sport centre with practice pitches and associated public realm and site infrastructure facilities in the heart of Al Ain city in United Arab Emirates. The architectural focal point of the development is the unique Hazza Bin Zayed Stadium and associated plaza's which without question represents one of the most modern, state-of-the-art stadia and facilities in the Middle East, materialized under the Main Contract of BAM international from the Netherlands. The aesthetic treatment of the stadium represents a modern facility combined with the traditional cultural elements of the United Emirates "Garden City" Al Ain, designed by Pattern (UK) Architects. The design integrates the palm tree in the palm bowl facade design concept. The design, manufacture and installation package of the palm bowl facade system was assigned to EFTCG Steel & Glass under the premise to guarantee an aggressive execution schedule of only 6 months from award to handover. EFTCG Steel & Glass Germany developed a unitized concept for the Diagrid Facade Package by implementing parametric design criteria. These were generated by in-house software for the detailing and manufacture of the individual facade elements, which is comprised of straight members and 3D cross connectors . The LSG approach allowed 100% pre-manufactured finished light weight elements which were only to be bolted together manually on site with minimum equipment requirements. The comprehensive approach of the main contractor, its consultant's team with Schlaich Bergermann and Partners (SBP) as well as close coordination with other trade and sub-contractors in combination with EFTCG Steel & Glass' chosen design concept demonstrates our capability to perform technically challenging very fast track projects in an economic environment.  

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GLASS STRUCTURES

Using modern lamination techniques, as well as new developments within Glass production, LSG is able to design large-span complex glass only structures. Incorporating the latest glass technology almost any design is now achievable.

CUSTOM-MADE STEEL AND GLASS SOLUTIONS
 

Custom-made steel and glass solutions are specialist developed systems which meet the clients' demands in almost any aspects. The combination of variable supporting structures together with almost all kind of envelopes (e.g. photovoltaic panels, curved glass, stone, composite panels or louvres) is nearly unlimited. Our experienced engineers will be able to determine the technical feasibility of any kind of structure even at a very early stage of the project.

 
SERVICES AND ENGINEERING

A RELIABLE PARTNER FROM START TO FINISH AND BEYOND
You can rely on EFTCG's professional service at every stage of your project. With an exclusive partner network, going back many years EFTCG provides the ultimate in knowledge and expertise for guaranteed superior quality.
Our excellent manufacturing capacity ensures quick delivery and efficient installation of all products and, once the handover is complete, rest assured you will continue to receive EFTCG's personal service and top-quality customer care.


CONSULTING
Our in-house Sales and Estimating department is able to provide early stage support for all Architects, Consultants and Contractors to help develop their aspirations into realised solutions.
Our System Designers and Engineers are available to develop early stage architectural intent into engineered solutions to meet the demands of all modern day facades.
We are able to offer commercial advice and support at the earliest possible phase of a project so that budget expectations are understood by the client team from the very outset. Value-engineered solutions can be proposed in parallel offering the client choices as designs evolve.
In conjunction with the technical and commercial challenges, our highly experienced Operations teams are able to provide planning and installation resolutions for the most complex of facades ensuring that safe and efficient methodologies are implemented with our proposals in line with programme constraints.
Comprehensive bid proposals are prepared through our Sales and Estimating resources in our London, Dubai, Arlesheim and Arnstorf office, incorporating Group expertise during the tender phase and beyond, especially for adjustments at interfaces with interior works. This ensures that continuity of all the necessary tender information is maintained and carried forward into awarded projects.


GREEN BUILDING MANAGEMENT
 
EFTCG is experienced in projects with international Green Building certification systems such as LEED, breeam and DGNB. We profit for those special requirements from a close contact with our EFTCG Green Building department having deep expertise knowledge in how to best carry out such projects. We can provide you extensive consulting in Green Building standards and how to turn them effectively into reality.
For our system developments, the highest Green Building standards, energy saving and material cycle systems like Cradle to Cradle have a very high priority. We are also able to provide environmental product declarations in ISO 14021 standard for our Facade systems, where the performances in those categories are summarized.


PROJECT MANAGEMENT
EFFECTIVE PLANNING FROM START TO FINISH

At EFTCG Facades we know the key to a successful project is meticulous planning, communication and, above all else, experienced specialist facade project management. All of our project managers are experienced in bespoke unitised facades, and our management structure ensures that each project team has hands-on support and guidance operationally at director level.
For us, a successful project starts even before it is awarded. Right from the beginning, our operations staff is involved actively in all tenders to ensure our client proposals are based on well-thought-out programmes, and that our logistics and installation methodologies are tailored to the particular project challenges and constraints. By doing this, if we are successful then both our clients and our team have the confidence that our schemes are based on sound planning and workable methodologies.


DEDICATED PROJECT TEAMS
Unlike many of our competitors, all of our projects have dedicated full-time project teams. These teams are based locally at our worldwide offices, e.g in our UK office in Putney, London during the off-site, lead-in activities but when the project approaches the site phase, the whole project team bases itself full-time onsite, thereby ensuring direct control over operations on a day-to-day basis and face-to-face client communication.
Our project managers have direct contact with all of our design offices and, of course, our production facility in Arnstorf, Germany, where each project has its own full-time dedicated internal project manager to ensure the day-to-day project priorities are achieved.


COMMUNICATION-DRIVEN PROJECT MANAGEMENT
Regular internal face-to-face focus meetings in Germany ensure our project managers have full control over all aspects of the project at all times and, again unlike our competitors, can give up-to-the-minute information to our clients across all aspects of their projects.
Our project management structure, systems and procedures ensure our teams follow a collaborative approach with open and honest communication both internally and externally with regular reports on each project strand. 


DESIGN AND ENGINEERING
EXPERIENCED TECHNICAL EXPERTS

The design of quality bespoke unitised facades requires a high level of technical ability and experience. At EFTCG we have some of the most technically competent and experienced people in the business. Furthermore, the own fundamental apprenticeship and employee development programs for our younger colleagues are a key principle of EFTCG Facades.
Our specialist facade System Design Office, based in Arlesheim, Switzerland, can take a facade from concept to reality, no matter how challenging. Supported by our own in-house facade, structural, thermal and acoustic engineers, facade designs are tailored to suit individual project performance specifications and aesthetic requirements.


EXTENSIVE DESIGN RESOURCE AND FACILITIES
With substantial design resources in offices in the UK, Germany, Switzerland and in the UAE, we have the capacity to design multiple complex projects at the same time. So whether your project requires complex 3D geometry, challenging performance, or both, EFTCG can provide you with the solution to make your facade concept a reality in the desired timeframe.


TESTING AND MOCK-UP
 
PROJECT-SPECIFIC APPROACH
Bespoke unitised curtain walling is, by its very nature, unique and project-specific. To achieve each solution, it is necessary to design project-specific aluminium profiles and gaskets that meet both the aesthetics and specific performance criteria required by clients.


BRINGING DESIGNS TO LIFE IN MOCK-UP FORMAT
Taking project-specific profiles and gaskets from the drawing board to final production requires a significant lead-in. For this reason we also offer our clients the facility to see their designs come to life earlier in the process by building full size mock-ups made from timber and/or alternative materials prior to the production of the project-specific materials, which can have long lead times. These “Visual Mock-Ups" (or VMUs) can then act as a benchmark for the final design and materials, and are generally built and assembled for viewing at our factory in Arnstorf, offering clients the opportunity to visit our headquarters at the same time.


PERFORMANCE TESTING AND MUCH MORE
As well as VMUs we also produce “Performance Mock-Ups or PMUs”. These mock-ups are produced from the final approved and project-specific materials for the sole purpose of performing the testing of the required standard to prove the air permeability, water resistance and structural integrity of the system prior to going to full production. The facade units for these tests are produced in Germany and shipped to the selected accredited test centre.
In order to guarantee the quality within the whole production time, we also do regular tests similar to those at the institutes at our own test stand in Arnstorf production (FPC). Our in-house R&D Department also carries out certified project-specific testing of system parts, such as impact testing of glass, cyclic testing of vents and many other types of tests which are often required when designing bespoke systems that must comply with the various standards and regulations. We can also provide acoustic testing in our own independently accredited laboratory within our Arnstorf factory.


PRODUCTION
 
IN-HOUSE, STATE-OF-THE-ART PRODUCTION FACILITY

Our facade production facility is based in the EFTCG Group’s ‘home town’ of Arnstorf in Bavaria, Germany, and sits directly adjacent to the main EFTCG headquarters and production facilities for our internal fit-out products.
As you drive into the village of Arnstorf from the direction of Munich, our facade factory and offices are on the left hand side. Here, we have our own dedicated 20,000 sqm facade production facility housing state-of-the-art specialist machinery, automated profile storage and two-storey production halls. This facility alone is capable of producing up to 140,000 sqm of high quality unitised curtain walling per year. In addition to this, should the requirement arise, we have the facility to use additional machining capacity and production for pressed metal from our other factories on the site, which covers a further 145,000 sqm in area.
Quality and production expertise is the very foundation of the EFTCG Group, and in our Arnstorf home this can be seen in every hall and every product. We look forward to welcoming clients and potential clients alike and giving you a guided tour of this impressive facility.


INSTALLATION
 
DELIVERING HIGH QUALITY FACADES ON TIME, SAFELY

At EFTCG Facades we understand just how important the planning and management of the installation phase is to the successful handover of a completed high quality facade to our clients, safely and on time. For this reason, our planning starts from the very first project meetings, and our installation managers are engaged early on in the process to ensure their valuable experience is fed into our design, planning and logistics strategies.


FULLY CONNECTED SITE SET-UP
Our site set-up is substantial in comparison to most of our competitors, with the whole project team being based full-time on site. And to ensure that everyone can communicate and work efficiently, our site office networks have fast broadband connections to all our various offices around the world.


TRIED AND TESTED INSTALLATION TECHNIQUES
Our innovative installation methodologies are tried and tested, and tailored to suit individual project constraints. Installing unitised curtain wall at height is our core business and, as such, we have robust systems to manage and control all aspects of our installation activities.


EXCELLENT SAFETY RECORDS
Safety is at the heart of everything we do of course and in contrast to many of our competitors, we allocate a full-time safety manager to each of our major projects, not only to ensure our own works are installed safely but also to engage actively with the client teams and those of our fellow trade contractors, making sure the whole site environment is one where everyone can go home safe at the end of their shift. EFTCG Facades has recently completed over two million man hours RIDDOR-free, an achievement of which we are very proud.
All of our projects are audited monthly on-site for health and safety, environmental and quality performance, with the results reviewed at board level. This ensures that the service and performance we promise our clients are being achieved on-site.


MAINTENANCE AND AFTER SALES
EFTCG Facades has their own dedicated service teams which carry out a full range of maintenance and after sales works to the building envelope, ranging from the replacement of a single pane of glass through to the re-cladding of an entire facade. With our specialist knowledge and equipment, we are able to undertake the most complex of repairs with minimal disruption to the building occupants, liaising as necessary with statutory and local authorities, insurers and your specialist advisors.
As further part of EFTCG Facades Group, Berlin-based company EFTCG Rido is specialised for the inspectation, maintenance and repair for the building envelope. The team's projects, independent from the Facades Group projects, contain both engineered solutions as well as the craftmanship with their own installation teams.

 
ACCREDITATIONS

EFTCG Facades recognises that it must integrate its business values and operations to meet the expectations of its stakeholders, which include customers, employees, regulators, investors, suppliers, the community and the environment.

We realise that our social, economic and environmental responsibilities to these stakeholders are integral to our business and aim to demonstrate them through our actions, within our corporate policies and through the correct use and continual improvement of our Integrated Management System.

We take all feedback received from stakeholders seriously and will be open and honest when communicating our strategies, targets, performance and governance to them, as part of our continual commitment to sustainable development.

We ensure that all the necessary resources are available in order to realise our corporate obligations and responsibility for our performance towards corporate social responsibility rests with all employees throughout the company.

Our various certifications in international standards for health & safety, quality and environmental management as well as memberships in several associations proof our motivation and responsibility.

HEALTH AND SAFETY MANAGEMENT
A safe working environment is at the heart of everything we do and our uncompromising approach to the safety of every employee, client and supplier is a cornerstone of the EFTCG Facades belief system.

An uncompromising approach to health and safety Every single one of our construction projects has a tailored and collaborative approach to health and safety, no matter what size or level of complexity. With health and safety at the very core of our business, our aim is to be recognised as the safest building envelope contractor in the UK and our other markets – ensuring no harm to our people, surrounding trades or the public. We set demanding key performance indicators, measure our goals, minimise our risks and ensure we conform to and maintain the BS OHSAS 18001:2007 standard of accreditation.

Also, we achieve successful certification to Achilles and CHAS on a consistent basis. Our experienced health and safety managers, and external consultants, carry out frequent inspections on each site and office, and senior management and directors regularly undertake tours of our projects. Without exception, information gathered from performance measurements and audits is always reviewed and lessons learned are cascaded into the business.

WE CREATE THE RIGHT CULTURE
Health and safety is integrated into every aspect of our work processes and thus we encourage and engage with employees, creating a safe working culture and resulting in continuous improvement. Safety for us is a mindset and an attitude adopted by everyone from our managing director to our newest recruit; it is not only viewed and stated simply as our number one priority, it is always considered a core value that is instilled in all areas of our company. Our people are encouraged to report all near misses or any change in conditions straight away. We ensure that everyone is in a position to identify risks on a daily basis. This is valued highly by our clients and main contractors, and has significantly contributed towards constantly improving our own health and safety record. We also recognise that communication is key to our success, and our Health and Safety Forums provide an invaluable framework for consultation.

CURRENT HEALTH AND SAFETY STATISTICS

 

  • Over 2 million man hours worked RIDDOR free

  • Zero Prohibition Notices

  • Zero Improvement Notices

  • AFR of 0.0 for the last four years
     

QUALITY MANAGEMENT
It is the policy of the company to provide services of a consistently high quality to our customers, and to establish the objectives and processes necessary to deliver results in accordance with both customer and legal requirements.

EFTCG Facades, in its pursuance of achieving long lasting success, is committed to enhancing customer satisfaction by consistently providing a quality of service that meets or exceeds client requirements and expectations, and to provide such service in a manner, which ensures the safety of customers, staff and any third parties. The best way to achieve this is by continuously auditing our processes. When areas for change are identified they will be introduced following careful assessment, including a cost benefit analysis, to ensure the improvement of the service to our clients, and the enhancement of the management system as a whole.

Our commitment to continual improvement has been rewarded with the ISO 9001:2015 certification for its Quality Management System.

We pride ourselves too on implementing and complying with all requirements of the Integrated Quality, Environmental and Safety Management System and any other applicable requirements. Quality requirements are met with defined management responsibility in place to ensure that all members of staff are adequately trained and are fully familiar with the company’s commitment to providing services of a consistently high quality to our clients.

ENVIRONMENTAL MANAGEMENT
EFTCG Facades believes that in the pursuance of achieving long lasting success, it must be environmentally aware and, for this reason, is committed to operating an effective Environmental Management System (EMS) as part of an integrated framework for sustainable environmental stewardship. Our EMS complies with all applicable environmental legislative, client and local community requirements. The EMS is integrated within EFTCG Group’s mission to protect human health and safeguard the environment. This is accomplished through setting targets for environmental stewardship, reducing or preventing pollution, preserving environmental resources, and the use of ecologically tested and acceptable materials wherever possible.

The EMS establishes EFTCG Facades’ commitment to environmental performance. We do this through a process of continual improvement, creating strategic objectives and targets, maximising opportunities, and measuring our environmental performance with the primary target of reducing our carbon footprint to a minimum.

EFTCG Facades’ EMS is certified with the ISO 14001:2015 and is designed, amongst other things, to meet the following goals:

  • Ensure compliance by meeting or exceeding all applicable environmental legislative and other requirements

  • Strive to continually improve environmental performance in terms of both regulated and unregulated environmental impacts

  • Provide for a safe and healthy work environment so that our employees are enabled to participate in improving our environmental performance

  • Promote employee awareness and involvement as a means of achieving high performance results and better understanding of the potential benefits of our EMS