Crystal Campus – Waterford

Crystal Campus – Waterford
Address: Cork Road, Waterford, Ireland
Project: Crystal Campus Development (Waterford Crystal site)
Completion: 2025 (scheduled)
Architect: Fewer Harrington & Partners, Waterford
Client/Developer: Frisby Homes
Main Contractor: Vetra Construction Limited
Façade Contractor: AluFactory Ltd

Scope of Work
AluFactory was appointed to deliver the complete façade package for the landmark Crystal Campus redevelopment. Central to our scope was the design, manufacture, and installation of a unitised façade system combined with aluminium rainscreen cladding, creating a modern and high-performance building envelope.
Key elements included:
• Unitised Curtain Walls: Bespoke façades engineered with Reynaers CW50-HI / CW65-EF profiles, integrating large glazed spans, spandrels, and ventilation systems.
• Aluminium Rainscreen Cladding: 3 mm aluminium panels finished in RAL 9003, seamlessly connected to the curtain wall units for architectural consistency.
• Glazing Systems: High-performance SunGuard 70/35 coated IGUs with argon-filled cavities, laminated Low-E panes, and acoustic interlayers, delivering U-values as low as 0.5 W/m²K and Rw up to 43 dB.
• Spandrel Panels: Opaque glass in RAL 7016, maintaining visual rhythm and performance across elevations.
• Ventilation Louvres: DucoGrille Solid F systems with plenum boxes, engineered to handle 250 l/s airflow while maintaining thermal and acoustic integrity.
• Doors & Ironmongery: Fully integrated package including Dormakaba ED100/250 automated swing doors, WSS panic hardware, Sobinco cylinders, and fail-safe electric strikes.
• Structural Integration: Brackets, spigots, cast-in channels, and slab connections engineered to Eurocode standards, with site-specific wind loading calculations (up to ±2.97 kN/m²).

Profile System
• Reynaers CW50-HI – Stick curtain wall system for complex façades.
• Reynaers CW65-EF – Unitised façade modules, prefabricated for precision and rapid installation.
• Reynaers CS77 & ML8 – Access door and framing systems designed for high-traffic use and heavy-duty ironmongery.
Glazing Details
• GL1: Triple glazing – U = 0.5 W/m²K | VLT 61.7% | Rw 39 dB
• GL2: Laminated acoustic glazing – U = 0.6 W/m²K | Rw 43 dB
• GL3: Double glazing with laminated inner pane – U = 1.1 W/m²K | Rw 39 dB
• GL4: Enhanced laminated glazing – U = 1.1 W/m²K | Rw 39 dB
• GL5: Special transparent glass build-ups for non-BS6262 compliant internal façades
Performance
• Thermal Efficiency: Overall unitised façade U-value = 0.68 W/m²K
• Wind Resistance: Designed to withstand pressures of up to ±2.97 kN/m²
• Acoustic Control: Glazing achieving sound reduction up to Rw 43 dB
• Condensation Safety: Verified at surface temps ≥15.9°C, with humidity safety margins of 70–88%
Key Features
• Complete Unitised Façade Delivery: Curtain wall systems combined with aluminium rainscreen cladding, installed as a coordinated package.
• Architectural Impact: Sleek RAL 7016 framing contrasted against RAL 9003 rainscreen to create a modern and striking identity.
• Innovation in Execution: Blend of unitised modules (off-site fabricated) and stick curtain walling for flexibility and efficiency.
• Access & Safety: Integrated automated doors, panic escape hardware, and access control systems in compliance with EN1125 and Part M.
• Sustainability: High thermal and acoustic performance, ensuring long-term comfort, energy efficiency, and reduced carbon footprint.
AluFactory’s work on the Crystal Campus – Waterford highlights our capability to deliver complex unitised façade systems with aluminium rainscreen integration. In collaboration with Fewer Harrington & Partners and Vetra Construction Limited, we provided a durable, sustainable, and architecturally distinguished building envelope that sets a new benchmark for design and performance in Waterford.