The partnership between Reynaers Aluminium, a developer and manufacturer of system solutions for facades, windows and doors, and EVB (prior to rebranding - "Euroviknobud"), a Ukrainian engineering and facade company with 28 years of experience in the design, processing of systems, production and installation of aluminum structures, is a case of integration into international projects through regulatory discipline, engineering coordination and quality control at all stages. We will understand the logic of the global market for complex facade solutions with the help of speakers: Anatoly Chegusov, CEO of EVB, Andriy Dudar, CEO of Reynaers Aluminium in Ukraine, and design engineer of Reynaers Aluminium Serhiy Starodub.
Prefabrication for export
The facade of a modern building is no longer a costume that decorates or hides the structure. In many cases, it becomes a real "spacesuit": a finely tuned shell that protects against the aggressive external environment - from hurricane winds and rains, from extreme temperature drops, from city noise and dust, from fire risks, from the human factor. Outstanding opportunities, but also great responsibility: an unsuccessful seam, a missed tolerance, and the result - repair costs, and sometimes direct threats to safety and operation.
That is why in complex projects the facade ceases to be an autonomous element of architecture and turns into a shared area of responsibility and a clear division of roles: who forms the engineering parameters of the system and sets the design loads, who is responsible for the design, the quality of manufacturing in the workshop, and who guarantees that the finished element will pass the necessary tests and be installed without missing deadlines.
The partnership model of cooperation between Reynaers Aluminium and the Ukrainian company EVB has been taking shape since the 2010s. It began with the implementation of mullion-transom facades for Ukrainian facilities and the synchronization of technologies, quality control, and compliance with Belgian regulations.
View of Hadrian's Tower in Newcastle upon Tyne: a 27-storey tower where a precast façade from Reynaers Aluminium and EVB ensures precision engineering and full compliance with British regulations. Photo © Hufton + Crow. Photo courtesy of Reynaers Aluminium
In world practice, the classic approach — assembling the facade directly on the construction site — is still widely used today. At the same time, with increasing height, more complicated geometry, and higher requirements for tightness, element facades are becoming increasingly important. In such solutions, critical operations — assembling large modules, insulation, and sealing — are transferred to a controlled production environment.
Prefabrication can be a practical solution when production is not located near the site, but hundreds of kilometers away. For example, when modules are transported from Kyiv to Lviv. But the application of a Ukrainian manufacturer to participate in a tender in the UK back in the conventionally "pre-war" 2017 sounded like an application to pass a real quest: certification, protocols, multi-level control. In architecture, there is always a risk when "expats" are involved - even if it is a top architect with a world name. Without a local partner who knows the context and regulatory framework, the project risks getting stuck at the adaptation stage. In our case, we are talking about the reverse movement: the export of not individual parts, but entire large-format facade elements from Ukraine to the UK.
Prefabrication not only reduces logistics and site costs, it also radically speeds up installation: the elements are fixed from inside the building using a compact manipulator on the upper floors, without external scaffolding.
The Ukrainian EVB team, in collaboration with Reynaers Aluminium, first entered the tender for the element facade for Hadrian's Tower in Newcastle upon Tyne. Construction started in 2018, and key tests and production of elements were already taking place in COVID-19 conditions. The first shipments of finished elements from Ukraine took place in 2020. The second case is Compass at Curzon Circle in Birmingham: the active phase of production, testing and logistics fell on 2021. Here, construction continued during the pandemic, and the final completion coincided with the first year of full-scale invasion. In the spring of 2022, shipments from Ukraine temporarily stopped, but by the end of April, logistics were restored, which allowed for the completion of installation.
This path — with forced pauses and resumption of supplies in difficult conditions — became a practical test of the element facade from Reynaers Aluminium and its adaptations, as well as the effectiveness of the chosen model of interaction between project participants.
The implementation confirmed that, under conditions of proper engineering coordination, a structured contract process, and compliance with local market requirements, a Ukrainian manufacturer can integrate into projects with high technical standards and operate in an environment with increased requirements for quality control, logistics, and documentation.
Hadrian's Tower as Newcastle's new landmark: harmoniously fitting into the city's historic context with elegant lines and a glass façade with high energy performance. Photo © Hufton + Crow. Photo courtesy of Reynaers Aluminium
High threshold of entry: discipline, finances, responsibility
British cases for EVB became an entry into an environment where the rules of the game are strictly formalized. According to the CEO of EVB Anatoly Chegusova, the difficulty lay not in a separate technical task, but in a combination of factors - organizational, financial, and contractual.
Anatoly Chegusov, CEO of EVB
Anatoly Chegusov: "First, it is the language barrier and the specifics of professional communication. To work in the UK, a general knowledge of English is not enough - you need to understand construction professional jargon, a large number of abbreviations and local language features. Some of the meetings took place in the north of England, where there is a specific accent, which makes it difficult to understand even for people who have studied English since childhood. Without the participation of British colleagues in the team, a significant part of the information could simply be lost. At the same time, the British culture of project management has a strong side: after each meeting, detailed minutes are drawn up, and all open issues are transferred from one protocol to another until they are fully resolved. This significantly reduces the risk of misunderstandings.
Secondly, access to finance is a critical factor. The British model of construction contracts assumes that the contractor finances the purchase of materials, production and logistics independently. Payment is made only after the products are delivered to the site - usually after 60-90 days. In addition, it is necessary to provide performance bonds and bear other associated costs. Without access to equity or debt capital, the implementation of projects in the UK is practically impossible.
“The British model means total formalization of processes. No verbal agreements — every decision must be documented, tracked, and reproduced. Transparency and traceability are part of the contract culture,” — Anatoliy Chegusov
Thirdly, the complexity of the project's organizational structure. At all facilities, EVB worked through a general contractor. In addition to him, a key role is played by an architect and an independent facade consultant - a participant who is practically absent in typical Ukrainian practice. Facade consultants check each element of the project, and they are interested not only in the correctness of the decision, but also in the justification of each figure and the calculation methodology.
In addition, the mandatory 12-year warranty is not just a declaration, but a set of specific engineering and organizational solutions, which inevitably affects the overall economics of the project, as it requires increased requirements for materials, inspections, and quality control."
Anatoly Chegusov explains that the step into the zone of increased requirements was quite conscious. The first barrier is formal, but fundamental: without ISO 9001 certification, a company simply does not pass prequalification for tenders; in many cases, ISO 14001 is also mandatory. "The British model means total formalization of processes. No verbal approvals - every decision must be documented, tracked and reproduced. Transparency and traceability are part of the contract culture.
The second aspect is a strict implementation sequence. Before the start of production, a full-scale mockup is made, followed by test samples and mandatory CWCT tests. (tests developed by the standards organization - the Center for Window and Cladding Technology. - Ed. note), if necessary, additional ones, including acoustic ones. Only after confirming the results does serial production start.
Installation of a custom-designed facade system on Hadrian's Tower. Photo courtesy of Reynaers Aluminum
Separate unit - fire safety requirements significantly strengthened after Grenfell Tower (The Grenfell Tower fire in London on June 14, 2017, killed 72 people when flames quickly spread through the building's exterior cladding. The conclusion of an independent investigation highlighted systemic failures in the use of combustible materials and in fire safety controls. — Ed. note). These are different materials, different logic of nodes and responsibilities. For the Ukrainian manufacturer, this was not just a new market, but a transition to a different level of engineering discipline."
Point of application of effort. Help from PRAGMATIKA.MEDIA
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Hadrian's Tower in Newcastle - a 27-story tower 82 meters high on Rutherford Street, designed by FaulknerBrowns for developer The High Street Group.
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Compass (Curzon Circle) in Birmingham - a 15-storey trapezoidal building on the eastern edge of the city, adjacent to HS2 station, Gosta Green and the Birmingham City University and Aston campuses. Designed by Glancy Nicholls Architects for Torsion Group and completed in 2022.
Unitised facades in dense urban development
The choice of facade system for large-scale projects in the UK is determined not only by architectural expressiveness, but above all by the predictability of the technical result, the speed of implementation and compliance with the complex urban construction conditions. In this context, the element facade system from Reynaers Aluminium was considered as a technologically sound unified solution.
The finished cassettes are assembled in-house using automated CNC centers. This optimizes the process, increases accuracy, and reduces waste. As noted Andriy Dudar, CEO of Reynaers Aluminium in Ukraine, element facades are an ideal option for urban conditions: “Dense urban development, complex logistics — all this imposes restrictions. When you build in the city center, the traffic pattern can even be changed for the object. And all this is strictly limited in time. In such conditions, it is critically important to minimize the area occupied by the construction. A traditional facade is always a warehouse on the site: insulation, pyramids with double-glazed windows, profiles, consumables. Space is needed for storage and phased installation. An element facade (for example, ElementFaçade 7) is delivered to the object already with the double-glazed window, insulation, and all components installed. It is lifted and installed. There is no need to organize separate storage areas, there are no intermediate operations on the site.”
Andriy Dudar, General Director of Reynaers Aluminium in Ukraine
Prefabrication radically speeds up installation: elements are fixed from inside the building using a compact manipulator on the upper floors, without external scaffolding and construction cradles.
Andriy Dudar emphasizes: "A lifting mechanism or a small manipulator that works one level higher or two floors higher is enough. A team of four people installs element by element. This saves space, time, and human resources, which is especially relevant now."
If you delve into the technical characteristics of ElementFaçade 7 (EF-7), you will notice its adaptive qualities: the system withstands wind loads of more than 5000 Pa (i.e., it is able to withstand extreme conditions - hurricane-force winds), and, unlike more rigid post-and-beam structures, it effectively compensates for seismic vibrations thanks to independent elements connected by flexible seals. The variability of EF-7 turns it into a tool for ambitious projects. The system easily accepts external decorative elements and adapts to complex geometry - glass corners or sun-shielding slats.
So EF-7 doesn't just optimize the process, it turns the facade into a predictable structural element in demanding and even extreme conditions.
FaulknerBrowns’ ambitious project in Newcastle upon Tyne was successfully completed despite the pandemic and logistical challenges. Photo courtesy of Reynaers Aluminium
Chain of Responsibility and Role Engineering
Most element facades are individual engineering products. In such a configuration, the joint work of the fabricator and the system supplier is a basic condition. For Hadrian's Tower in Newcastle - the tallest building in the city, exposed to northerly winds from the Tyne - the requirements for wind resistance and tightness were the maximum for the region. In Birmingham, on Compass, the nature of the loads is different: there is less height, but there is proximity to a large transport interchange, constant vibration, acoustic pressure, cyclic influences. In both cases, the system had to prove not declarative, but measurable stability.
Andriy Dudar says: "Elementary facades are always designed for a specific architecture and construction of the building. For example, Hadrian's Tower has a structural element facade with integrated decorative panels and a system of horizontal and vertical slats. In the Compass project in Birmingham, the configuration is different: integrated panels and pronounced vertical decorative elements.
In such cases, the supplier works with the request generated by the processor and, together with it, develops an engineering solution adapted to the specific object."
The manufacturer's early involvement in the design allows for a sober assessment of the scale of the task: the volume of elements, the complexity of the geometry, the associated junctions, decorative modules, logistics. And, no less importantly, its own production capabilities.
Preparation for CWCT tests is another example of the division of roles. Reynaers prepares the drawings, calculates and orders the aluminum system, creates the manufacturing catalog. EVB calculates and orders the related materials and directly manufactures the elements under the technical supervision of the system supplier.
For EVB, working with Reynaers significantly increases the predictability of the outcome due to access to international expertise and comprehensive support at all levels.
Anatoly Chegusov notes: “EVB worked with Reynaers’ international technical support center and their specialists, who have experience in implementing a large number of complex projects around the world. This allows us to use proven technical solutions, quickly find optimal engineering approaches and avoid typical risks on complex sites.
Detail of the east façade of Compass (Curzon Circle) in Birmingham: Reynaers’ highly insulated façade element system is adapted for high-rise construction and combines aesthetics with energy efficiency. Photo: Glancy Nicholls Architects
The local Reynaers office in the UK also plays an important role. Its specialists participated in meetings with the customer, helped adapt the solution to local regulations and promptly resolved technical issues directly on site.
At the same time, the key factor in success was the support of the Kyiv office of Reynaers. Without this, the implementation of projects in this format would have been practically impossible. EVB received invaluable technical assistance, timely deliveries of materials, as well as special financing conditions that allowed it to work within the framework of the British model of deferred payments.
Compass (Curzon Circle) in Birmingham: 15-storey tower with a trapezoidal plan and facade by Reynaers Aluminium. Photo courtesy of Reynaers Aluminium
Tests and certification
A facade can be perfectly designed in a digital model and confirmed by calculations. However, the final assessment of its effectiveness is given by full-scale tests. In the test chamber, a fragment of the facade is subjected to controlled loads: excess and negative pressure are created, slanting rain is simulated, and resistance to shock impacts is checked. It is at this stage that theoretical solutions undergo practical verification.
The testing procedure begins after the design is complete — when the architectural and engineering solutions are agreed upon, the manufacturer is selected, and the system is prepared for serial production. This is not a concept search stage, but a stage of confirming the compliance of the implemented solution with the established technical parameters and project requirements.
The manufacturer's internal tests are not enough. Each object underwent a separate independent verification at the initiative of the investor and the facade consultant. Samples manufactured by EVB in Ukraine were delivered to the Reynaers Technology Centre in Duffel (Belgium) - one of the most powerful private testing centres in Europe. Certified test stands were installed here for a full cycle of tests: air permeability, water tightness, wind load resistance, impact resistance.
Serhiy Starodub, the leading design engineer of Reynaers Aluminium in Ukraine, explains the details of the procedure: “An independent inspector, hired by the investor, comes to the testing, who personally conducts checks exclusively with his own calibrated equipment. According to British protocols, the most severe scenarios are reproduced - from wind and water loading to impact tests. All parameters are documented, down to the smallest details.”
Serhiy Starodub, leading design engineer at Reynaers Aluminium in Ukraine
In the case of Hadrian's Tower and Compass (Curzon), the system passed a full cycle of independent verification without the need for constructive improvements. The formation of the final report is the area of responsibility of the certification party. Preparation of documentation can take up to a month. The manufacturer's team is present during the tests and receives protocols, but does not influence the procedure for forming conclusions.
After confirmation of compliance, the serial production stage began in Ukraine. The aluminum profile system came from Belgium for further painting and thermal insulation. Fully equipped cassettes were assembled in Kyiv - with double-glazed windows, insulation, junction units, integrated decorative elements. The finished modules were loaded into heavy trucks and sent to the UK through EU countries.
Compass in context: The building's dynamic form, with a low blue brick plinth and a distinctive metal roof, does not clash with the historic brickwork of Birmingham Railway Station. Photo courtesy of Reynaers Aluminium
Anatoly Chegusov: “Deliveries are organised on a just-in-time basis with no intermediate warehouses in the UK. The products are packaged in such a way that they can be assembled in the reverse order of unloading. The packaging must provide full protection during long transport.
Planning is also extremely important. On British sites, a detailed schedule of work is drawn up for all contractors. For example, on one project in Newcastle, the installation of bathrooms in apartments was carried out through the facade, so the facade could not be closed earlier. Such interdependencies are tightly coordinated between all construction participants.
Competitiveness without origin discounts
A logical question: why can't the customer localize production directly in the UK or the EU, and despite the complex logistics, different regulations, and a multi-level audit system, EVB's proposal won the tender?
There are several reasons. The first is the pace. European production culture involves a clearly regulated working day, mandatory breaks, and a complete shutdown on public holidays. This approach creates stability, but it affects the speed of implementation of large contracts, especially when deadlines are tight. The second is workload. Most manufacturers in the EU work with long queues of orders, which automatically extends the project entry cycle. The third is experience with complex high-rise buildings. EVB systematically works with non-standard components, large formats, and strict engineering requirements. A significant part of Kyiv's high-rise buildings was implemented by this team, and this is accumulated expertise.
Competitiveness was ensured by the speed of decision-making, production discipline and the ability to work in a mode of high engineering responsibility. It was these parameters that allowed the Ukrainian enterprise to integrate into an international contract without compromising on quality.
So, it is not about the factor of "cheap labor". Competitiveness was ensured by the speed of decision-making, production discipline and the ability to work in a mode of high engineering responsibility. It was these parameters that allowed the Ukrainian enterprise to integrate into an international contract without compromising on quality.
Systematicity test: what has changed for brands and teams
British cases became not only a test of technical solutions, but also a test of institutional maturity. For the Ukrainian market, it was a marker: whether the local team would be able to work according to the rules of one of the strictest regulatory systems in Europe — and not just pass an audit, but complete the project.
Andriy Dudar, General Director of Reynaers Aluminium in Ukraine: “The implementation of joint projects with EVB in the UK has become an important stage of professional practice for us within the framework of the British contract model. In such a system, the facade solution undergoes a full verification cycle: from engineering integration and manufacturing of a test sample to independent laboratory tests in accordance with CWCT protocols. Technical parameters are confirmed not only by calculations, but also by physical tests in specialized testing centers.
Such projects involve coordination between all participants in the facade process: system supplier, manufacturer, facade consultants, engineers and notified bodies supervising the tests. We were involved in the preparation of technical solutions, support of tests and approval of structural components within the design process.
The practice of such projects forms a different logic of working with facade systems: a significant part of technical solutions is checked before the start of construction, and the process is accompanied by detailed documentation and coordination between the parties.
The experience gained has strengthened our competence in the full cycle of facade engineering — from early integration of system solutions to confirmation of their characteristics during testing — and expanded our practice of working in projects with increased technical requirements.”
For EVB, this international contract stimulated the transformation of internal processes.
Anatoly Chegusov, EVB CEO, concludes: "Preparation for work in the British market changed the company from the inside. Obtaining ISO 9001 certification and the requirements of the contract model led to the systematic formalization of quality management. Clearly defined procedures, documentation, and the ability to track each decision appeared.
We have significantly improved the level of planning, project coordination and quality control. But the human factor is no less important. The implementation of complex projects in the UK has become a powerful “pumping” for the team: competences, confidence and motivation have increased.
Today we understand: if a company is able to work in one of the most demanding markets in the world, it is able to work in almost any country. And this experience is already influencing how we implement projects in Ukraine.”
TBC Bank headquarters in Tbilisi, Georgia. The project by Dutch office UNStudio was realized in collaboration with teams from six countries. Photo courtesy of EVB
Point of professional maturity
It can be said that the British experience became a point of structural correction for the collaboration participants: from early integration of engineering to the full cycle of testing, documentation and distribution of responsibility. The following international objects have already followed the proven algorithm. In this sense, participation in the implementation of the new headquarters of TBC Bank in Tbilisi was indicative. To embody the architectural image, the Dutch bureau UNStudio designed a complex element facade with a two-component structure: an internal cassette and external decorative slats with built-in lighting from Expolight. The total mass of one element reached 600 kg, which created additional loads on the system. The integration of engineering required non-standard solutions, in particular, 3D printing of frame fragments for preliminary testing of cable laying. Teams from six countries joined the collaboration, and the testing included a full cycle of CWCT with seismic tests. The production of test samples was carried out by EVB, with each stage recorded in accordance with the protocol. Despite its complexity, the system passed the tests without any complaints. In fact, the entire process was built on the experience gained in British projects.
Ukrainian teams have demonstrated the ability to work within the logic of the global market as equal partners, shaping the result, and not just providing its production part. Therefore, it is not surprising that the Ukrainian manufacturer becomes an equal participant in the international chain of technical responsibility and the full cycle of facade engineering. This model — partnership, technically disciplined and scalable — outlines the potential for complex projects abroad and in Ukraine.
