Darke Tech : Case Study 1

Darke Tech case study - Highbury Grove School, Islington - design and construction of bespoke aluminium earth tubes (ventilation funnels) with polyester powder coating.

When international architects practice BDP designed the external ventilation funnels or 'earth tubes' to be positioned in the playground area of Highbury Grove School, London, Darke were asked to consider taking on the project.

A job no one else could tackle

Several other suppliers had already been approached by the contractors but none were able to take it on due to the bespoke nature and its complexity. However Darke's reputation preceded them and they were approached directly by the architects who already knew that they could tackle this type of problematic project.

A big problem

BDP supplied drawings and directed MD Tony Darke to one of BDP previous contracts at The University of East London where the design had been used before – it seemed like a lot of fuss over nothing. However on visiting the site the problem became apparent. The previous ones were only 750mm diameter whilst at Highbury they would need to be significantly larger at 1850mm. The only way to achieve this diameter would be to roll the tubes individually in the workshop before construction of the vents.

Two further problems also quickly became apparent. The construction site had restricted access which meant they would have to be constructed, hand carried and erected in two halves. The other was the timescale – all work had to be completed and installed before the end of the school holidays.

A bespoke all aluminium solution

Darke's experience in this type of project is second to none and they were able to take on the challenge of bespoke design and construction all to a tight timescale. After careful consideration it was decided to build them in 4mm aluminium sheet which had the advantages of lightness for manual handling and good corrosion resistance. It also allowed for the creation of the double curve louvers which could then be welded in the Earth tube prior to polyester powder coating.

Darke's own engineers then installed the earth tubes on site whilst working to the strict health and safety regulations laid down by the construction company involved with the project. The final result was a bright and eco-friendly addition to the school completed on budget and all ready for when the children returned from their holidays.