What about fire?
What about infestation?
Won’t the straw decompose?
What about damp?
What about mould?
What sizes do they come in?
Can I get different sized panels than the standard?
How thick are the panels?
Why are they so thick?
Does ModCell™ help towards the thermal mass of the building?
What are the u-Values?
What about Carbon?
How are they made?
What are they made of?
How heavy are they?
Are they sustainable?
Is there waste from the manufacturing process?
Do they cut noise levels?
Are there different finishes available?
How do you incorporate essential services like plumbing and electricity?
Are they load bearing/structural?
How high can you build with them?
Can I build with a frame?
Do you build them onsite?
Where are they made?
What quality controls do you have?
What is the lead time?
How long do they take to install?
What equipment is needed to install them?
Can I buy them in kit form?
Do you supply to self builders?
Can you help me with my design?
How long do they last?
How long is their warranty?
How much do they cost?
Where can I get my building insured?
Do you supply complete building packages?
Where can I see one?
If you have more questions please contact us and we will be happy to help you.
What about fire? [Back to top]
ModCell Straw™ bales are tightly packed and covered with Lime render. Fire needs a ready supply of oxygen to burn and without it no combustion will occur. The panels provide a near airless environment, so fire resistance is very good. Recent tests show a fire rating of 2 hours for ModCell Straw™ and over 2 hours for ModCell Hemp™.
What about infestation? [Back to top]
Straw contains very little nutritional value and will not, in itself, support a pest population. The density of straw discourages rodent activity. Infestation can only occur when panel has been damaged and straw is open to external atmosphere. ModCell Hemp™ is a monolithic structure not dissimilar to lightweight aerated concrete and as such prevents infestation occurring. Lime render is aseptic further reducing the possibility of infestation.
Won’t the straw decompose? [Back to top]
ModCell™ panels are designed to be breathable and prevent the buildup of humidity levels. It is high humidity levels that causes decomposition to take place. Straw begins to decompose when the moisture content exceeds 25%. Our researc has shownthat the moisture content of ModCell™ is less than 15%, well below the level at which decomposition becomes a potential risk.
What about damp? [Back to top]
ModCell™ is delivered to site as closed panels with all but the finishing surface skim coat lime render applied. Relative Humidity (RH) and moisture levels are measured at the factory gate. Research has shown that damp is kept at bay naturally as part of the breathable properties of the materials used
What about mould? [Back to top]
Lime is aseptic. The Relative Humidity, moisture content and air changes from the panels 'breathing' prevent fungal and microbial activity.
What sizes do they come in? [Back to top]
Standard sizes are 1m x 3m, 2m x 3m and 3m x 3.2m; other panel sizes are available on request.
Can I get different sized panels than the standard? [Back to top]
Yes, we can manufacture panels outside our usual standard dimensions. If you require these please contact ModCell™ to discuss.
How thick are the panels? [Back to top]
ModCell Straw™ panels are 490mm thick.
Why are they so thick? [Back to top]
To accommodate standard size UK straw bales. To meet the same u-Value using brick block and mineral wool, insulation the wall would need to be 533mm thick.
Does ModCell™ help towards the thermal mass of the building? [Back to top]
ModCell™ has an optimum combination of mass and super insulation. ModCell Hemp™ has higher thermal mass than ModCell Straw™. Both products deliver a thermal lag of 8 hours, which is optimal for most uses.
What are the u-Values? [Back to top]
This is dependent on the panel type:
490 mm ModCell Straw™ = 0.13
490 mm ModCell Hemp™ = 0.14
300 mm ModCell Hemp™ = 0.22
ModCell™ solid timber frame = 0.13
Insulation values are nearly 3 times higher than current regulations require.
ModCell™ panels deliver an airtight construction, to PassivHaus specifications. As a result, buildings using ModCell™ can help deliver zero heat requirements, saving money and CO2 emissions. BaleHaus™ has an air tightness of 1m2/(h.m2) at 50Pa , 10 times better than current regulations require.
What about Carbon? [Back to top]
ModCell™ panels are 'carbon negative'. Embodied carbon - A 3 x 3.2m ModCell panel has equivalent of 750kg of atmospheric CO2 locked up in its fabric. A typical two story BaleHaus of 100m2 banks almost 30 tonnes of atmospheric CO2
How are they made? [Back to top]
The structural timber frame is ‘infilled’ with locally sourced straw bales, which are stacked to form a wall, compressed and pinned together for stability. The wall is then either plastered using a protective lime render or clad with timber.
What are they made of? [Back to top]
Straw bale or Hemcrete, timber, lime render or wood cladding and small quantities of steel fixings. ModCell™ is made of by-product wood, infilled with straw or hemp. They are precision-engineered using modern methods of construction.
How heavy are they? [Back to top]
Weight varies by panel size. A fully rendered 3m x 3.2m weighs approximately 1.7t
Are they sustainable? [Back to top]
Yes, ModCell™ panels are made from 100% renewable materials. ModCell Panel™ frames are constructed using PEFC timber as standard. FSC certified timber can be sourced on request. All straw, which is by-product of the agricultural industry, is untreated and locally sourced. . ModCell Hemp™ uses hemp grown as a field crop in the UK, a field of hemp has a different biodiversity profile to that of straw, but we know of no adverse impact.
Is there waste from the manufacturing process? [Back to top]
Straw bales are cut to size in the Flying Factory and trimmings and rejected material are composted, used as bedding for farm animals or recovered as biomass. The frame is made using offcuts from the timber industry. Cut materials from the frame manufacturing process are used in the factory’s biomass boiler. Cut waste is minimal as each panel is precision cut from larger sheets using CNC equipment. Lime render is spray applied with almost no residual waste. Offcuts of stainless steel and are minimised by the design but are collected and recycled via the scrap industry.
Do they cut noise levels? [Back to top]
Yes they produce an approximate reduction of 70db
Are there different finishes available? [Back to top]
Yes, These include uncoloured Lime render, pigmented Lime render, Lime wash colour finishes and timber cladding. Customers who require alternative finishes should contact us to discuss their requirements.
How do you incorporate essential services like plumbing and electricity? [Back to top]
The frames of ModCell™ can incorporate pre-routered conduit at 150 mm centres as an option. The face of the panel can have this fitted in the factory upon request.
Are they load bearing/structural? [Back to top]
Yes, with some considerations. On commercial buildings ModCell™ is normally secured to a building frame. For domestic construction ModCell™ can be used for structural load bearing and stabilisation. Normally Modcell™ panels are structural up to 3 stories high. Above this height we would advise the use of ModCell™ panels as a panelling system fixed to a frame.
How high can you build with them? [Back to top]
Structurally up to three stories high.
Can I build with a frame? [Back to top]
Yes, Modcell™ can be used with timber, steel and concrete frames.
Do you build them onsite? [Back to top]
No, ModCell™ is an offsite prefabricated panel system - (see below)
Where are they made? [Back to top]
In order to minimise the embodied energy in ModCell™ Panels we fabricate them in 'Flying Factories'. Instead of using a central fabrication plant and transporting ModCell™ Panels great distances, we work with local farmers to identify a source of straw and a suitable location to assemble ModCell™ panels, normally within 10 miles of the construction site. By using local straw, skills and labour, we are able to keep more of the project’s value within the local economy.
What quality controls do you have? [Back to top]
ModCell™ panels are entirely manufactured and assembled under controlled conditions in 'Flying Factories'. The quality of each panel is uniform and signed off at various stages during manufacture. ModCell™ is delivered to site as closed panels with a two-layer base coat of lime render. Relative Humidity and moisture levels are measured at the factory gate.
What is the lead time? [Back to top]
16 weeks from confirmed order.
How long do they take to install?
ModCell™ is delivered to site in nominal 3m x 3.2m panels, although other sizes are available to.. To offload from low loader and secure on to building is typically a 20 min operation giving an install rate of 27sqm per hour. Complexity/simplicity of project will impact on this rate. Final finish coat of render is done at a later date and each panel takes half an hour. This can be achieved off of a 'cherry picker', or more usually from a scaffold.
What equipment is needed to install them? [Back to top]
Crane or telescopic lifting device.
Can I buy them in kit form? [Back to top]
No. Currently manufacturing quality controls prevent the manufacture outside of factory environments. Although we are happy to engage with community groups and individuals who want to assemble panels. This would be after appropriate training and supervision.
Do you supply to self builders? [Back to top]
This is dependent on the size of the development and will reviewed on a case by case basis. Additional traveling distances from 'Flying Factories' may have an effect on cost per unit and an increase in CO2 emissions.
Can you help me with my design? [Back to top]
Yes ModCell™are able to offer a number of service options to the developer. These include:
supply, supply & fit, design & supply, design, supply & fit, consultancy and CPD training.
How long do they last? [Back to top]
Life cycle is in excess of 100 years. At end of life they can be easily reused or disassembled. Lime can be re-used. straw, hemp and wood are biodegradable and can be used as biomass. Hemcrete™ can be crushed and mixed into soils. All metal fixings can be recovered and recycled. There are a number of straw bale buildings throughout the world, some of which are over 120 years old.
How long is their warranty? [Back to top]
ModCell™ offers up to a 50 year warranty.
How much do they cost? [Back to top]
£250-£270 per square metre.
Where can I get my building insured? [Back to top]
There are a number of insurance brokers who offer insurance, an example is M & DH Insurance Services Ltd (www.mdh-insurance.co.uk).
Do you supply complete building packages? [Back to top]
ModCell™ are able to offer a number of different packages. These vary from supply only, supply and fit, supply design and fit. BaleHaus™ is our whole house solution.
Where can I see one? [Back to top]
There are a number of sites around England and Wales. These include:
Archimedia, Knowle West, Bristol, England.
York EcoDepot, York, England.
Torfaen EcoBuilding, Cwmbran Wales .
Faculty of the built Environment, University of West England, Bristol, England.