Historical Context and Manufacturing Background

The Falcon House, a notable example of system-built properties, emerged during the 1960s, a period marked by a significant demand for rapid and cost-effective housing solutions in the UK. This demand was driven by post-war housing shortages and the need for quick urban development. The Falcon House was manufactured by J & J Dean (Contracts) Ltd, with designs by L J A Wilkinson. These properties were primarily constructed to provide affordable housing options and were built in substantial numbers across various urban and suburban locations.

Design and Construction Characteristics

General Features

Falcon Houses are typically 2- and 3-storey structures, identifiable by their shallow pitch gable roofs covered with tiles or bituminous felt. Some variants feature flat roofs also covered with bituminous felt. The front and rear external walls are often finished with sprayed texture asbestos cement sheets, plywood, or shiplap timber boarding. The gable walls are constructed using wide storey-height precast reinforced concrete (PRC) panels with a sprayed textured finish or brick with narrow storey-height PRC panels at the ends.

Substructure and Main Frame

The substructure of Falcon Houses consists of PRC slabs and PRC edge beams. The main frame is a timber structure, with storey-height timber frame panels clad with asbestos cement sheets up to the first-floor level and shiplap timber boarding above. These panels are lined with Asbestolux, a material known for its fire-resistant properties but also for containing asbestos, which poses health risks if disturbed.

External and Internal Walls

The external walls are insulated with polystyrene between the frame studs, providing some thermal efficiency. The flank walls are typically brick with cavity insulation and storey-height polystyrene insulated PRC panels. The separating walls between properties are constructed using large storey-height polystyrene insulated PRC panels, ensuring structural integrity and some degree of sound insulation.

Floors and Ceilings

The ground floor is a PRC slab, while the upper floors are made of large PRC floor panels. Ceilings are finished with a sprayed texture, often directly onto the concrete panels, which can present challenges for maintenance and repair.

Roof Structure

The roof structure varies between properties. Some feature timber trussed rafters with PRC or timber purlins, covered with bituminous felt and tiles. Variants include roofs covered with butyl/neoprene or bituminous felt pre-bonded to Stramit slabs, and flat roofs made of PRC slabs with butyl/neoprene or bituminous felt.

Typical Hazards and Risks

Asbestos

One of the most significant hazards associated with Falcon Houses is the presence of asbestos, particularly in the Asbestolux lining of the walls and the sprayed texture finish on the external walls. Asbestos poses severe health risks if disturbed, leading to respiratory diseases and cancers. It is crucial to handle any renovation or repair work involving asbestos with extreme caution, employing licensed professionals for asbestos removal and disposal.

Structural Integrity

The use of PRC panels in the construction of Falcon Houses can lead to issues with structural integrity over time. PRC panels are prone to carbonation, a process where carbon dioxide from the air penetrates the concrete, leading to the corrosion of the steel reinforcement within. This can compromise the strength and stability of the structure. Regular inspections and maintenance are essential to identify and address any signs of deterioration.

Thermal Efficiency

While the polystyrene insulation provides some thermal efficiency, Falcon Houses may not meet modern energy efficiency standards. Upgrading insulation and installing energy-efficient windows and doors can help improve the thermal performance of these properties, reducing energy costs and improving comfort.

Water Ingress and Damp

Flat roofs and shallow pitch gable roofs covered with bituminous felt are susceptible to water ingress and damp issues. Regular maintenance of the roof covering and ensuring proper drainage can help mitigate these risks. Additionally, the presence of asbestos cement sheets on the external walls can lead to moisture retention, exacerbating damp problems.

Defective Premises Act Considerations

Falcon Houses are not specifically listed as defective under the Defective Premises Act. However, the presence of asbestos and potential structural issues with PRC panels necessitate careful consideration and thorough inspections before purchase. It is advisable to engage a qualified surveyor to assess the condition of the property and identify any potential defects or hazards.

Inspection and Maintenance Guide

External Inspection

1. Roof: Check for signs of wear and tear on the roof covering, including cracks, blisters, or missing tiles. Inspect flat roofs for pooling water and ensure proper drainage.
2. Walls: Look for cracks, bulging, or other signs of structural movement in the PRC panels and brickwork. Pay particular attention to the condition of the asbestos cement sheets and shiplap timber boarding.
3. Windows and Doors: Ensure that windows and doors are in good condition, with no signs of rot, warping, or damage. Check for proper sealing to prevent drafts and water ingress.

Internal Inspection

1. Walls and Ceilings: Inspect for signs of damp, mould, or condensation, particularly in areas with Asbestolux lining. Look for cracks or other signs of structural movement in the PRC panels.
2. Floors: Check for unevenness, sagging, or other signs of structural issues in the PRC floor panels. Ensure that floor coverings are in good condition and free from damage.
3. Insulation: Assess the condition of the polystyrene insulation in the walls and roof. Consider upgrading insulation to improve thermal efficiency and reduce energy costs.

Structural Assessment

1. PRC Panels: Engage a qualified surveyor to assess the condition of the PRC panels, checking for signs of carbonation and corrosion of the steel reinforcement. Follow the guidance provided in BRE Digest 444 and BR 254 for inspection and maintenance of reinforced concrete.
2. Timber Frame: Inspect the timber frame for signs of rot, insect infestation, or other damage. Ensure that any issues are addressed promptly to maintain the structural integrity of the property.

Asbestos Management

1. Identification: Identify all areas containing asbestos, including Asbestolux lining and asbestos cement sheets. Ensure that these areas are clearly marked and documented.
2. Management Plan: Develop an asbestos management plan, outlining procedures for handling, maintenance, and removal of asbestos-containing materials. Engage licensed professionals for any work involving asbestos.
3. Regular Monitoring: Conduct regular inspections to monitor the condition of asbestos-containing materials, ensuring that they remain undisturbed and in good condition.

Common Defects and Remedial Actions

Cracking and Movement

Cracking and movement in PRC panels and brickwork can indicate structural issues. Engage a qualified surveyor to assess the extent of the damage and recommend appropriate remedial actions, such as reinforcing or replacing affected panels.

Damp and Mould

Damp and mould issues can arise from water ingress through the roof or walls. Address the source of the moisture, such as repairing roof coverings or improving drainage. Consider installing a damp-proof course and upgrading insulation to prevent future issues.

Asbestos Degradation

Asbestos-containing materials can degrade over time, releasing harmful fibres into the air. Engage licensed professionals to safely remove and dispose of degraded asbestos materials. Consider replacing asbestos cement sheets with modern, non-hazardous alternatives.

Thermal Efficiency Upgrades

Improving the thermal efficiency of Falcon Houses can enhance comfort and reduce energy costs. Consider upgrading insulation in the walls and roof, installing energy-efficient windows and doors, and implementing other energy-saving measures, such as draught-proofing and installing a modern heating system.

Conclusion

Falcon Houses, with their distinctive design and construction, offer a unique housing option for home buyers and investors. However, the presence of asbestos and potential structural issues with PRC panels necessitate careful consideration and thorough inspections before purchase. By understanding the typical characteristics, hazards, and maintenance requirements of Falcon Houses, buyers can make informed decisions and ensure the long-term safety and comfort of their investment.

At Flettons, we’re committed to safeguarding your investment. When considering a property purchase, trust our seasoned expertise to reveal any hidden threats. For a thorough building survey, get your instant quote through our quote calculator or reach out directly at 0203 691 0451. Your home’s safety is our top priority.

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