Synergistic association between the Lorillard Group and BuildUp materialized on a pioneering site in Wattrelos

The challenge extends to the European level, where 43 million homes must undertake energy renovation to achieve the goal of carbon neutrality by 2050.

Renovation players, while essential in this business, also face the challenge of reducing their carbon footprint on construction sites. It is in this context that the collaboration between the Lorillard Group and the Belgian provider of off-site solutions, BuildUp, takes on its full meaning.

For almost two years, these partners have joined forces to contribute to the energy renovation of social housing in the Hauts-de-France region. Their collaboration is based on a common vision of the importance of energy renovation, both for reducing energy poverty and for the carbon footprint of construction sites. Together, they are actively engaged in this monumental undertaking, highlighting their potential to reduce greenhouse gas emissions and shape a more sustainable future.

^{*Figures from the 2022 report of the French Ministry of Ecological Transition on the performance of the housing stock.
**National Observatory for Energy Renovation July 2022}

Wattrelos pioneering site

It is in Wattrelos that an unprecedented collaboration between the builder BuildUp and the Lorillard Group took shape, in partnership with the social landlord Vilogia, a versatile player acting as lessor, builder, developer, promoter, and co-ownership trustee.

Vilogia, housing around 400 residents in a district of Wattrelos, comprising 160 terraced houses dating from the 60s, became aware of the need to renovate these accommodations. Knowing Lorillard Bâtiment's expertise in the renovation of joinery and facades on occupied sites, Vilogia invited the brand to participate in its innovative renovation project.

The lessor opted for the “Energie Sprong” method, originating from the Netherlands, for the renovation of its buildings. This approach is based on methods of industrialization of renovation and places emphasis on the results to be achieved rather than on specific methods to be followed, thus offering an innovative approach to the modernization of housing.

A revolutionary off-site process

BuildUp undertook a revolutionary design process based on precise specifications. To do this, the builder carried out detailed surveys of the existing facades, which were then carefully transcribed into specialized software. These surveys make it possible to precisely anticipate the necessary equipment and their location, taking into account the individual developments made over time (verandas, extensions, storerooms, etc.).

This step made it possible to create a precise digital representation of the future prefabricated construction elements and to plan the harmonious integration of existing equipment into the facade modules.

This digital approach offers many advantages, including the significant reduction of waste generated while guaranteeing zero margin for error, thanks to rigorous digital design. Based on these surveys and digital modeling of the neighborhood, BuildUp designed the new facades and roofs, aligned with the requirements of the specifications. However, the concrete realization of the facade elements required the expertise of the Lorillard Group.

Lorillard, a partner with high added value

Based on the information provided by BuildUp, the Lorillard Group has developed a PVC joinery prototype specifically intended for horizontal installation. Particular attention was paid to waterproofing, with adjustments to the vapor barrier and insulation to ensure a perfect seal of the chassis. The installation surfaces have been adapted by integrating a rebate into the wood for optimal protection of the Compriband. In addition, Lorillard has also created custom-made fixing brackets – and supplied the plans with the fixing brackets – in order to avoid any drilling when fixing each joinery. This joinery proved to be not only thermally efficient, but also remarkably suited to the Belgian partner's machining process.

Also, the roller shutter boxes were subjected to technical development by the C2F team, an entity of the Lorillard Group, in collaboration with the Research & Development department. As part of this project, given that the facade cladding completely surrounded the roller shutter box, it was essential that the box was accessible from below. An adaptation was made so that the box does not open from the interior side of the facade, but rather from below, thus simplifying subsequent maintenance interventions.

Thus, the Lorillard Group manufactured a total of 454 white PVC joinery from the Design 5 range (designed within the Group by C2F), 283 roller shutters, and 153 PVC entrance doors (designed within the Group by Plastibaie ). These elements were assembled off-site, in a workshop on the Build Up manufacturing line. Particular attention was paid to the airtightness of the joinery and doors, with the support of the technical expertise of the staff of the Lorillard Bâtiment Hauts-de-France agency.

All the elements were assembled in Aarschot, before being shipped without delay to Wattrelos. The result of this collaboration is impressive, combining both aesthetic appearance and energy efficiency. In a record time of just 10 months, at a rate of 7 houses per day, the 160 homes initially classified in energy category F were transformed into real high energy performance homes, bearing the A+ label. These homes are now models of energy neutrality, representing a significant milestone in the field of renovation; model rightly honored with a mention in the “Urban Renovation” category
during the 2022 edition of the Construction 21 “Green Solutions Awards”, for a BEPOS renovation which represents the largest EnergieSprong renovation carried out in France.

For Hélène de Troostembergh, CEO BuildUp: « Our collaboration with the Lorillard Group and Lorillard Bâtiment has been very positive for our company. Their sense of partnership, their expertise and their ability to adapt to best respond to the technical particularities of our machining line have made it possible to enrich our renovation project. Together, we have worked to create housing of exceptional quality and exemplary in terms of energy. »

The partnership between BuildUp and the Lorillard Group is not limited to the supply of facade elements. It is a partnership that is fully committed to each stage of the construction and renovation process, from design to implementation on the ground. Lorillard Bâtiment site managers provide technical support for the necessary adjustments to be made on site and the finishes on each dwelling. This attention to detail ensures that each element of the construction is perfectly adjusted and complies with the requirements of the project.

For Damien Leroy, Manager of the Lorillard Bâtiment Hauts-de-France Agency: « Our technical support is support, a local presence which guarantees that each construction or renovation project takes place smoothly, efficiently and in accordance with the expectations of our partner BuildUp and the client. »

This approach illustrates their commitment to excellence and customer satisfaction, making them a partner of choice for BuildUp and its modular construction projects. An approach which has notably been renewed in France, in Roubaix, on a building of collective buildings.

The Lorillard Bâtiment team supported the general building company Dujardin (at the origin of the connection between Lorillard Bâtiment and BuildUp) and the BuildUp company in the energy renovation of 32 homes, with the design and assembly outside site of 140 PVC windows, interior roller shutters and shutters.

BuildUp, or the future of resilient, sustainable housing with a lower ecological impact

BuildUp is a Belgian company specializing in digitalized prefabricated construction. At the heart of their approach is a principle of radical energy neutrality, where buildings do not consume more energy than they produce. BuildUp has developed an innovative concept that begins with scanning and taking precise measurements of the existing building. This data is then used at the factory in Aarschot, Belgium, to produce complete facades and roofs, including insulation, windows and doors.

The walls and roofs are built using layers of certified materials, without concrete. They are then installed as an insulating envelope around the existing building. Additionally, energy-efficient solutions, such as solar panels and heat pumps, can be integrated. The entire construction process is designed to be circular and, wherever possible, based on bio-based materials.

For Hélène de Troostembergh CEO of BuildUp: « We imagine changing the way we build houses to make them like cars. With less room for error, more control over quality, and a thousand times more efficiency. »

Indeed, the factory pre-assembly system ensures optimal quality, perfect airtightness of the joinery elements, a reduction in waste (which also reduces costs) and a zero margin for error thanks to the design digital.

The dynamic collaboration between the Lorillard Group and BuildUp aims to demonstrate the possibility of equipping buildings with a climate envelope in just 24 hours, by highlighting high-performance solutions and the potential of prefabricated construction. This approach skillfully combines sustainability and energy efficiency.

The construction industry is expected to play an essential role in achieving greenhouse gas emissions reduction targets. The Wattrelos project, intended for the rapid energy renovation of millions of precarious buildings, must serve as an example in terms of resilience, improvement of the quality of life of residents, and contribution to the transition towards a more environmentally friendly future. .

By uniting their skills and expertise, the Lorillard Group and BuildUp are committed to promoting energy renovation in an efficient, sustainable and environmentally friendly manner, thus laying the foundations for positive transformation in the construction sector.