BBC finds major flaws in £41m estate's balconies

A resident points to where a balcony collapsed in November 2023 in the Weavers Quarter in Barking

Major structural flaws in balconies on a housing estate built by the multinational firm Bouygues UK have been found in a BBC investigation after one collapsed last year and concerns were raised about three others.

After the incident in November, 77 balconies on the Weavers Quarter in Barking were shored up with scaffolding and residents were told not to walk on them in case they would also crumble.

Tests carried out on behalf of the BBC found the materials used in a partially collapsed balcony was made from plywood more suitable for indoor use using "weak" glue and this wood may have been used in other balconies on the estate.

The firm has said there appeared to be discrepancies between the materials used and the specified design it sent to a subcontractor.

'We're scared our balcony will collapse'

Hundreds were told not to use their balconies amid fears about balcony construction by UK builder Bouygues

Angelo Fiorillo and his wife Laura say they're living in fear after a partial collapse of a balcony on their new build affordable housing estate

Health worker Angelo Fiorillo and his wife Laura, an early years teacher at a local nursery, poured their life savings into an affordable apartment on the Weavers Quarter, on the Gascoigne estate in 2019.

They were particularly drawn to the large balcony which their four-year-old son loved playing on.

But the couple are now among hundreds prevented from using their balcony after what happened in November.

"We don’t know if it’s safe to go on the balcony right now. We’re scared we'll wake up any day and the balcony will collapse," said Angelo.

Laura added: "I'm petrified. Any noise in the middle of the day you’re scared that something is happening on the balcony. I'm worried for our son's safety."

Emergency scaffolding has been erected around 79 balconies

Kinga Surowka lives under the collapsed balcony and says it was lucky there were no deaths or injuries

Kinga Surowka lives in the groundfloor flat under the balcony which fell down.

She said: "I was shocked.

"There was huge beams of steel, wood, heavy fallen onto my apartment. Spread across the street. It's horrible to think I could have died here with our kids.

"Luckily it was late at night."

The pavement outside is regularly used by children walking to the nearby school.

"Every morning the street is full of kids, it doesn't bear thinking about."

Scientist: 'Big fail' in construction material

Plywood was scientifically analysed for the BBC to see if it was fit for purpose

Dr Morwenna Spear says the type of wood should not be used in outdoor balconies

The BBC obtained samples of wood from the collapsed balcony in November which fixed heavy tiles to the steel frame of the balcony and potentially nearly 80 other balconies.

Samples were sent to the BioComposites Centre at Bangor University, one of the leading biological materials laboratories in the UK.

Scientific analysis found the plywood was made from a non-durable species of Poplar wood and a weak glue. It was totally unsuitable for outdoor use as it was so susceptible to decay and collapse.

The centre's research fellow Dr Morwenna Spear said: "In terms of the wood itself, it’s not a durable one, it shouldn’t be outdoors.

"In terms of the glue, it’s very weak when it gets wet, so it also shouldn’t be outdoors.

She concluded: "That product should be used indoors only, that’s a big fail on somebody’s part."

Residents have not been told when their flats will be back to normal or when the scaffolding that is meant to guard against the risk of potential collapse of nearly 80 balconies will be removed.

'We're waiting for another disaster to happen'

Multinational firm Bouygues UK apologised and said a subcontractor may have used the wrong material

Bouygues UK received £41.5m to build the estate.

The multinational company with a UK wing is ranked in the top five construction firms in terms of value of their projects over the last 12 months in the UK, with a total of £1.5bn in contracts, according to Glenigans, a construction intelligence firm.

In response to the BBC investigation, Bouygues UK said that safety in its buildings was its number one priority.

It added that the design and materials were carefully considered by their professional consultants and the approving authorities.

It also confirmed the balconies on the estate were prefabricated offsite by a subcontractor and "the materials used may not be those that were specified in the design. We take this extremely seriously".

The firm has apologised for the incident and the distress it has caused to residents.

While the balcony design was unique to this development, Bouygues UK has declined to confirm how many other balconies are actively being investigated for similar problems with similarly flawed materials.

The firm also said it was continuing to investigate and remediation work was under way.

Residents have not been told when their flats will be back to normal or scaffolding removed

Building surveyor Arnold Tarling has criticised the use of low-quality plywood, exposed by the BBC investigation.

He believes it testifies to an overall lack of regulation and enforcement in the new-build sector.

Mr Tarling said: "It's alarming. This was bound to fail. It’s atrocious, unforgivable."

"They used internal quality plywood on this building. Something you use for building cupboards in your kitchen or your bedroom."

"We’re waiting for another disaster to happen. It may be on a much smaller scale than Grenfell, but deaths and injuries we are going to have."

'We could have been killed'

Balconies have been reported as sagging for several years by residents

Residents like Matt Lismore say they have repeatedly warned the freeholder, Barking and Dagenham council

Residents who spoke to the BBC say they have reported issues with the balconies to Barking and Dagenham council for several years.

Their local authority is also the building's freeholder.

Leader of the Weavers Quarter Residents' Association, Matt Lismore, said: "You come to the realisation you could have been killed.

"You make all the right noises about the problem and still be put at risk.

"It fills you with horror."

Barking and Dagenham council, has said it "took immediate steps to impress upon Bouygues the need to ensure all balconies on the newly-rebuilt estate are safe" when they were made aware.

It has "welcomed" the BBC's investigation and said it was "shocked" that the evidence suggested Bouygues - a major international construction firm - "could not rely on the integrity of its supply chain".

This is not the first safety controversy for Bouygues.

In 2014, Bouygues UK was fined £175,000 when a worker was crushed to death at a hospital construction site.

In 2009, it was fined £160,000 after a Barking site worker was killed by a reversing vehicle.

Most recently in November 2023, Bouygues Construction was served an enforcement notice following the death of a worker in a traffic accident during construction of the Hinkley Point C nuclear plant in Somerset.

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