Plasterboard wastage rate cut in school build project

St. Cuthbert’s Business & Enterprise College was designed and built as part of the Building Schools for the Future (BSF) programme.

The project’s drylining package was awarded to Sound Interiors; determined to minimise waste, the company enlisted the help of Knauf’s technical services.

Knauf assisted with amending the school’s initial design to reduce the number of board types to 7 from over 10.

This allowed for greater flexibility in re-using offcuts.

The workers were also discouraged from using full boards, as they were paid an extra 20% for every square metre they installed using offcuts as a substitute.

Storing offcuts

To reduce waste further, the decision was made to store the offcuts inside the building within ‘quarantine’ areas.

The ‘quarantine’ or ‘recycling station’ spaces were secured by barriers to prevent general access. Sound Interiors agreed to take responsibility for the waste, which would not usually be allowed to be stored on site.

Offcuts that measured over 300mm were recorded before they were put into the storage area. This method enabled the project’s operatives to select suitable offcuts for use.

Wastage rate cut to 9%

Upon the project’s completion, the resulting wastage rate for plasterboard was 9%; this is below the industry average of between 15% and 25%.

By saving and re-using offcuts, the team improved efficiencies in site works and reduced the number of deliveries and resources required to manufacture the products.

The implemented waste saving measures also saved Sound Interiors over £2,000 in the cost of skip hire, as around five skips of plasterboard waste was saved.