The document outlines the construction process of The Knoll, a four-story residential nursing home in Deal, Kent, detailing the project stages from architectural planning to on-site erection. It describes the steps involved in manufacturing timber panels and highlights the installation process over several days, including the assembly of cassettes and panels, as well as the need for steel reinforcements. Finally, it touches on the completion phase where finishing touches are made after the building is signed off.

1. An OFP Case Study: The Knoll A four storey residential nursing project

2. Overview The Knoll, Nursing Home, Deal, Kent 4 storey build featuring a lift shaft throughout 38 residential rooms 2 storey ‘day room’ area Nurses office

3. Stage 1 – The plans 1. Elevations The architectural drawings are sent to OFP in CAD format for the design team to look through and assign to a designer.

4. Stage 1 – The plans 2. The architect’s CADs are then drawn up to suit timber frame using TRADA timber frame standards.

5. Stage 1 – The plans 3. Once the architects drawings have been approved by the client the designer can start the design process.

6. Stage 1 – The plans 4. When the timber frame drawings have been signed off by the client and the architect then the panels and floor cassettes can be generated. These are accurately engineered drawings used to produce the walls in the building. These are then sent to the production team and scheduled in to the factory.

7. Stage 2 – Manufacture The completed panel drawings are added to the production package and sent to the factory for manufacture.

8. Stage 2 – Manufacture After the design has been completed a CSV file is generated. This works in conjunction with our optimaster saw to produce a waste managed cutting list. 1. The quantity of timber required is calculated and loaded in to the saw. 2. The saw is electronically programmed for the scheduled works. 3. The timber is efficiently and accurately cut. This minimises any waste.

9. Stage 2 – Manufacture 4. The optimaster saw prints the exact position of each stud in the panel and its position within the building. 5. The timber is loaded in to the rack for the manufacture process to begin. 6. Each compartment is organised according to the timber reference.

10. Stage 2 – Manufacture 7. The timber is taken from the rack. 8. The panel is laid out on the manufacture bench with the panel drawing beside it. 9. The panel is assembled in a controlled environment to the designer’s specifications.

11. Stage 2 – Manufacture 10. The completed panel is loaded in to the plot stack. 12. The completed stack is taken to the loading bays ready to go to site… 11. The stack is checked for quality and accuracy.

12. Stage 3 – On site erection Once the panels have been manufactured the erection process can begin…

13. Stage 3 – On site erection Day One The first element to go to site is the soleplate. This is the footprint of the building. Duration: 1 day.

14. Stage 3 – On site erection Day Two Once the soleplate has been fitted the ground floor panels are delivered. 144 panels were installed over 2 days.

15. Stage 3 – On site erection Day Three Here we can see the landed and erected internal panels.

16. Stage 3 – On site erection Day Four If any steels are required in the build these can be sent as part of the production schedule. 32 steels were required in the ground floor in this project.

17. Stage 3 – On site erection Day Six Once the panels have been fitted the floors can start going in. 45 cassettes were landed in 2 days.

18. Stage 3 – On site erection Day Nine Once the cassettes have been fitted and decked the next floor can be installed. 144 panels were installed over 2 days.

19. Stage 3 – On site erection Day Nine Here you can see the external panels sheathed in OSB.

20. Stage 3 – On site erection Day Nine The first floor panels are in and ready for the second floor cassettes to be landed.

21. Stage 3 – On site erection

22. Stage 3 – On site erection Day Eleven The second floor cassettes are landed. 42 cassettes were landed in 2 days.

23. Stage 3 – On site erection Day Twelve The cassettes are decked out. The starter plate is then laid for the next stage of panels to be erected.

24. Stage 3 – On site erection Day Thirteen The 2F panels are landed and erected. 105 panels were landed in a day.

25. Stage 3 – On site erection

26. Stage 3 – On site erection Day Fifteen The third floor cassettes are landed. 17 cassettes were fitted in a day.

27. Stage 3 – On site erection

28. Stage 3 – On site erection Day Seventeen The third floor panels are landed. 49 panels are landed in a day.

29. Stage 3 – On site erection Day Seventeen The roof trusses are also landed with the 3F panels.

30. Stage 3 – On site erection

31. Stage 3 – On site erection Day Nineteen The roof timbers are fitted.

32. Stage 3 – On site erection

33. Stage 4 - Completion After OFP have completed the roof and the building is signed off the second fix can begin. Here are a number of recently completed projects illustrating OFP’s finished product…

34. Stage 4 – Completion

35. Stage 4 – Completion

36. Stage 4 – Completion