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THE INSIDE STORY
Welcome to the latest edition of Offsite Magazine. Inside this issue we cover plenty of ground, not least a report on a special industry recruitment survey undertaken with employees involved with several businesses that have exited the volumetric modular housing sector.
Offsite recruitment specialists ARV Solutions and offsite advisors Cogent Consulting surveyed a group of former employees from some well-known company names to understand the reasons volumetric modular housing has suffered so badly over the last few years. As readers will know, this slice of the offsite market attracted ‘disruptive’ and well-funded entrants but ultimately saw that initial optimism and bold claims of solving the UK’s housing crisis, met with the harsh realities of the construction marketplace and its many frustrations.
The survey confirms that voices inside the factory walls echo what was being seen and felt by the those outside them – failure rested on high start-up costs, too rapid growth, cash flow problems, regulatory barriers, immature supply chains, and poor integration between manufacturing and site teams. However, despite business failures, affected workers largely remain positive about volumetric technology itself, though critical of some management structures. Although the sector has clearly suffered huge setbacks,
its future potential – especially in delivering affordable housing through efficient, repeatable designs – remains strong.
Light steel frame and precast concrete are a main focus this issue. Ben Towe, Managing Director of Hadley Group, goes into some detail on the process of obtaining and maintaining certifications and accreditation. These necessary hurdles show that businesses are quality assured and serious about what they provide, but they can be complex and overwhelming for small businesses. As Ben points out, do not let this delay you as non-compliance can lead to costly setbacks.
Precast concrete finishes off this issue with two great pieces. One outlining why the material is key to transforming the healthcare estate and proving that offsite manufacture can ‘derisk’ projects and give confidence to those planning new hospitals. Finally, as the growth of AI, machine learning and the entire digital world continues to control our lives, the construction of data centres is developing as critical infrastructure and concrete’s all important thermal mass is significant.
Thanks as ever to our contributors, advertisers, and supporters for their help this issue. It is always genuinely appreciated.
Gary Ramsay Consultant Editor
Email: gary.ramsay@offsitemagazine.co.uk
COVER STORIES
Dan Westgate, Managing Director at Brilliant Ideas, outlines why their approach to innovation in construction is all about creating clever and simple solutions to create high impact for contractors and is not only about eye-wateringly expensive R&D.
A new industry survey undertaken by offsite recruitment specialists ARV Solutions and leading offsite advisors Cogent Consulting, has revealed a range of views from staff recently involved with the slowing down of the volumetric modular housing sector.
Frameclad recently opened its doors to visitors and provided an exclusive opportunity to tour its facilities in Kingswinford to better understand offsite manufacture and one of the UK’s leading light steel frame providers.
NEWS
08 | Industry News
News and developments from across the UK offsite industry and wider construction arena including: Polypipe Building Services’ white paper examines prefabricated water management systems, Buildoffsite seek to understand how better the UK offsite sector can address recurring challenges, and modular provider McAvoy reports revenue just over £75million.
Our special focus section starts with Mark Shepherd, Director at MPA Precast and MPA Masonry outlining how repeatable construction will help derisk healthcare projects plus FP McCann explain why precast concrete is ideal for the growth in data centres.
FEATURES
30 | Solving the Housing Crisis –Offsite to the Rescue
As housebuilders grapple with an increasingly volatile market, can offsite methods help get ‘Britain Building Again’ and boost capacity? Trevor Richards, Operations Director for offsite experts Cogent Consulting, explains how.
40 | Mark for Steel Quality
Certification and accreditation are critical elements of all building systems including light steel frame, as Ben Towe, Managing Director of Hadley Group and head of the LSFA explains.
42 | Connected Workflows for Offsite
Trimble’s Craig Johnson explores the value of connected construction for the offsite sector, with unique workflows giving manufacturers and contractors control throughout the project lifespan.
46 | The Circular Benefits of Modular Construction
Richard Hipkiss, Development Director for MPBA, explains how modular construction is playing a pivotal role in developing a more sustainable approach to construction.
48 | Community Creation
With the UK’s social housing crisis at a critical juncture, we spoke to Dick Shone, Managing Director of Boutique Modern, about what its ModernHome can deliver for housing providers
50 | MMC Ireland Hits the Mark Again
Bringing together key stakeholders, industry leaders, innovators and policymakers for a third landmark event – the MMC Ireland 2025 Conference was declared a resounding success.
56 | Living in the Military
Defence needs supporting infrastructure to match the increase in spending and as Ian Astley, Regional Director for Premier Modular points out, modular construction can help.
60 | Scoring Green Goals
With its environmental credentials and sustainability benefits not spoken about enough, how does offsite construction stack up against the UN’s Sustainability Development Goals?
66 | Driving Transformational Change
OFFSITE EXPO – the offsite sector’s flagship event – returns later this year with fresh features and a renewed impetus on demonstrating how offsite manufacture can transform our built environment.
SAFER FASTER CHEAPER & GREENER
Dan Westgate, Managing Director at Brilliant Ideas, outlines why their approach to innovation in construction is all about clever and simple solutions to create high impact for contractors.
Innovation can be eye-wateringly expensive when you combine the financials for research and development with the tooling, even for prototypes. But we’ve always fully embraced innovation, investing more than £500,000 to date, knowing that some products may never make it to market and others will rise to the top and be the jewels in our crown.
When we spot an opportunity and believe we’re onto something, we’ll have a responsible discussion and go for it, which is why our innovation portfolio is made up of 32 patents and rising. Every niche product fixes common problems on-site but in new ways, using different materials and designs.
Chris Massey is the visionary behind these fully-fledged inventions, he’s also our company CEO. He’s a real thinker, thrives on a challenge and has an extraordinary efficiency for spotting an unmet need in the market – meeting it with a safer, faster, cheaper and greener alternative. When someone comes to him seeking a solution
because they’ve hit a stumbling block, he’s in his element. Last year, a major steel work contractor got in touch because of an issue regarding expansion and contraction of precast concrete terracing components, caused by thermal effects. They wanted to create a free end movement on the supporting steel raker beams. Within two months of that conversation the Grout Box was born and used on Manchester’s Co-op Live building, Everton FC and Manchester City’s new stand – a great example of modular construction.
What is innovation?
The term 'innovation' is frequently thrown around in construction, but we question how well understood it actually is. We’ll hear or read about companies who maintain they are innovating, but on closer inspection it’s hard to see any real evidence of it.
Innovation doesn’t have to be hightech: it can be a smarter, simple solution that creates an impact for the main contractor, or the steel, precast, ground or façade contractor. Take our
load bearing plastic shims.
These generally sit between the supporting steel structure under modular precast concrete components and not normally visible when the building is complete. The flooring contractor places our temporary hole covers over service holes and removes them at the end of the project to be reused. Sandwiched between civil engineering and structural engineering are our interlocking aluminium load spreader mats, when specified by the temporary works engineers.
Smarter solutions for contractors
Hole Covers remove costs associated with joinery and timber. The small cover takes less than five-seconds to install and around 60 seconds for the large cover. Both are quick to remove and reuseable. Covering temporary holes in precast and insitu concrete floors, and metal deck floors, they are made from load rated recycled plastic in a highly visible bright yellow and safer and cheaper than timber board. The small Cover is 250mm x 250mm suitable for holes up to 200mm square
COVER STORY BRILLIANT IDEAS
3
and load tested to 150kg. The large Cover is 350mm x 350mm, covers holes up to 300mm square and load tested to 180kg.
Stacker Packers are load bearing plastic levelling shims, and good alternative to steel. An interlocking protrusion helps keep the load stack stable and locked into place, and a side profile interlock enables larger load areas to be created, with final adjustment away from the trapping fingers zone. Made from virgin high impact polystyrene with UV stabilisers Stackers overcomes yellowing and brittleness linked with prolonged exposure to UV rays which is critical to performance. Steel shims on the other hand don’t interlock, can slip out of position, heavier and more expensive than plastic.
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ALIMATS® is a modular load spread solution for cranes and powered access. Made from certified extruded aluminium with a patented interlock the lightweight modules can be offloaded and set-up by hand lowering the burden on-site of bringing in heavy machinery at an additional cost. Modules range from a mini0.58m mat to an extra-long 3.48m mat and used like a kit of parts by developing a solution to suit each site environment. ALIMATS® have been used under temporary cabins for pop concerts, propping systems used in the construction of nuclear submarines, rescue equipment during the maintenance of large attenuation tanks, over suspended floors for large track movers and as a 320m long access road on private ground.
Inflatable Safety Net Recovery System - have you ever considered how you would rescue an injured or unconscious colleague who has fallen into a safety net, or how long the rescue would take? Rescue is often overlooked because teammates are usually on hand to help their colleague climb out. But most method statements lack any real detail on the actual steps to take in recovering someone in lifethreatening instances such as injury or heart attack. We know from first-hand experience the faster the recovery the greater chance of survival. The Safety Net Recovery System is the fastest way of rescue after a fall from height in around three minutes.
Future innovations
Right now, two new innovations are in progress and include a patented Squeezepin, which is a carbon neutral cast-in cup replacing steel lifting pins. Chris is also in the final throws of developing an interlocking carbon neutral social housing system from a standard kit of parts utilising various technologies as a solution to tackling the UK housing shortage, with a longer-term view of positively impacting the global housing crisis.
To find out more or to trial our innovations visit: www.brilliantideasltd.co.uk
Images: 01. Dan Westgate, Managing Director, Brilliant Ideas 02-05. Simple and cost-effective ideas are as innovative as many high-tech options
UK INDUSTRY NEWS
Polypipe White Paper Demonstrates Prefabrication Advantages
Polypipe Building Services has released a white paper examining how prefabricated water management systems can address critical industry challenges, including the shortage of skilled labour and the demand for increased efficiencies.
The white paper presents the results of a rigorous research exercise, carefully designed to evaluate the overall efficiency of prefabricated HDPE drainage systems, compared to more traditional approaches. The findings demonstrate that these systems offer a 56% lower installed cost compared to on-site assembly of the same material and that there is
McAvoy Reports Strong UK & Ireland Growth
Leading modular space solutions provider McAvoy has reported a significant increase in revenue to just over £75million, with EBITDA growing to £9.3million in the 2023/24 financial year. The business, which is one of the UK and Ireland’s market leading providers of high-quality temporary and permanent modular buildings, attributes the positive 2023/24 financial year to a strong performance within its rental division, as well as increased sales in the period for its flexible space solutions.
Key projects contributing to this success include completion of Orsett Heath Academy in Essex, McAvoy’s largest project to date, providing space for 1,200 pupils. The project was delivered for the Department for Education (DfE) through the Mod C framework. It’s appointment to the Defence Infrastructure Organisation’s £2billion SLA programmatic approach framework via a joint venture
more than a 150% difference between cast iron and prefabricated HDPE. The white paper presents a comprehensive case, helping project managers and construction procurement professionals improve their knowledge on the relative merits of different materials and drainage system installation methods.
Andy Cullum, UK Managing Director at Polypipe Building Services, said: "Our research demonstrates that prefabrication is not just an alternative approach – it's a strategic solution to some of construction's most pressing challenges. The white paper reveals how prefabricated systems can reduce on-site installation time, decrease labour requirements, and improve project efficiency while guaranteeing the highest quality standards. We also know that this approach can enhance sustainability.
“With our Advantage Off-site Prefabrication Service there are minimal on-site fabrication and installation off-cuts, and any actual prefabrication waste is recycled efficiently at our factory. What makes the findings particularly valuable for construction professionals is the comprehensive analysis of realworld applications. We've examined every aspect of installation, from basic material costs to site logistics and testing, providing decision-makers with concrete data to support their specification choices.” The research exercise was conducted by industry expert John O'Reilly, formerly a senior director at major M&E contractor - Briggs & Forrester. The survey compared different drainage system materials and installation techniques and clearly measured the reductions in on-site installation time achieved with prefabricated solutions.
The study presents a very full picture of the way that prefabrication leads to multiple benefits on-site. As well as lowering base material costs and shortening installation time, fewer induction and supervisory days were needed. Prefabrication positively impacts logistics time and enables just-in-time delivery, which in turn reduces storage requirements and site congestion. Tooling costs are lower, and an analysis of on-site testing revealed that prefabricated HDPE was less prone to leaks. Prefabrication also enables in-factory testing which provides another level of reassurance.
The white paper also explores how the adoption of prefabrication techniques can create significant benefits on top of on-site time and cost savings – if considered at the design stage of a project as part of a DfMA approach. These benefits can include optimising the number of drainage and supply connections, maximising space utilisation and developing innovative solutions for confined spaces.
By adopting a broad view of the effects of prefabrication on the whole project lifecycle, this white paper offers unique insights into the relative merits of different approaches to water management systems in commercial construction projects. With offsite fabrication bringing huge reductions in onsite labour, helping to alleviate the problem of skills shortages, and dramatically reducing the number of trained installers required, the study clearly shows that prefabricated HDPE provides a highly cost-effective solution.
Source: www.polypipe.com
with Kier and continued success in healthcare, including a new mental health facility in Yorkshire and repeat projects for the Queen Elizabeth Hospital King’s Lynn NHS Foundation Trust.
Ron Clarke, CEO at McAvoy, said: “We are pleased to report a strong performance across the McAvoy Group, which reflects growing demand for our premium solutions in the UK and Ireland. With the continued support of our shareholders, we are strongly positioned to deliver modern, flexible, and sustainable buildings across the education, healthcare, commercial and pharma sectors. We anticipate
significant growth in the modular market as demand increases for cost effective sustainable buildings that are flexible, quick to deploy and cost effective.”
Looking ahead, McAvoy plans to drive continued growth through further investments in rental fleet expansion, manufacturing capability, with an emphasis on efficiency and cost optimisation. This will be supported by the deployment of innovative AI, AR and VR technologies, and a focus on workplace safety and people development.
Source: www.mcavoygroup.com
UK INDUSTRY NEWS
Urgent Government Support Needed to Close Skills Gap
According to a recent study, almost three quarters of industry professionals see the lack of government support as the main reason for the widening skills gap. The research, which was commissioned by Siniat the UK’s leading lightweight construction manufacturer, surveyed 200 respondents (contractors and sub-contractors) to determine causes of the skills crisis and gain an understanding of why so few young people are entering the sector or becoming qualified in a skilled trade.
The research found that 71% say that a lack of government support is preventing businesses from investing in apprenticeships, whilst the same number said that the lack of pathways for young people leaving college is the main reason apprentices are dropping out of construction-related courses at a staggering rate of 47%.
Further to this, 62% of respondents stated that a lack of structure in the education system is deterring young talent from remaining in the construction sector. While the lack of government support was identified as the core reason for the skills crisis, difficult economic conditions were also cited as a problem for firms looking to invest in the next generation.
Indeed, 67% cited extreme market volatility as one of the main reasons that firms could not invest in new talent and a further 66% of respondents stated that
the challenging market conditions meant that direct employment simply isn’t viable for main contractors or housebuilders.
However, there are possible solutions. Respondents claimed that firms do want to invest in more talent: they just need support to do so. In fact, 68% said that a concrete government strategy would encourage firms to invest in skills and talent, and almost 69% said that creating additional career entry points for new talent would reduce dropout rates among apprentices.
67% of respondents also said that a culture shift would help the construction industry to attract and retain talent. This argument was furthered by the fact that 68% of respondents said inadequate pay and poor working conditions was pushing people out of the sector while 66.5% stated that discrimination and sexism are causing skilled workers to leave for other jobs.
Etex’s Head of Marketing Andy Mudie stated: “It is clear that government support is essential to attracting young people into the construction industry. The industry is operating in a difficult economic climate, with small margins, and a market that has slumped in recent years. This makes it difficult for firms of any size to invest significant time and resource into supporting apprentices, but for SME’s and sole traders – who, as a sector, we heavily rely on to train and upskill new talent – it makes it near impossible.
“Businesses urgently need support to be able to onboard young talent. But, further to this, we need to look closely at the education system, the qualifications available, and the viability of End Point Assessments that make some courses feel inaccessible to young people. While the government has pledged £40 million to help deliver shorter apprenticeships in ‘key sectors’ we need action now. The industry needs a concrete government strategy that will both support businesses and reform the education system. Otherwise, it will be impossible for the government to meet its ambitious targets during the current parliament.”
Iain Mcilwee, CEO of the Finishes and Interiors Sector (FIS) added: “This research is timely and tells a concerning story. Politically, we have also failed to invest effectively in embedding adequate careers advice in schools and structure support for further education. Skills England has a huge challenge and, as we move through 2025, the full impact will start to be felt on housebuilding targets and the delivering the socio and economic potential of construction. A long-term strategy is essential, but in this we cannot fail to recognise the need to look at the immediacy of the problem and how we can better support employers in making the investment required in training.”
Source: www.siniat.co.uk
NEW RIBA APPROVED CPD
Design Guide for SFS (Steel Framing Systems)
A comprehensive and engaging opportunity to maintain or enhance your knowledge and expertise on SFS.
Topics included
» Building Safety Act & the Golden Thread
» Carbon Net Zero
» Resistance to Fire
» Framing Systems
» Standard Details
UK INDUSTRY NEWS
BOS Survey Seeks to Understand Downtime in Offsite Manufacturing
Buildoffsite (BOS) are undertaking a survey to understand how better the UK offsite sector can address a series of recurring challenges. A final document – the ‘Downtime Sprint Framework’ – will provide a clear, actionable roadmap for change.
Wetherby Wall Systems Launches ‘Below DPC’ Insulation System
Wetherby Wall Systems, part of the ROCKWOOL Group, is delighted to announce the launch of SOQEL A2, a fully compliant, impact-resistant, and moisture-protected External Wall Insulation (EWI) system designed for below damp-proof course (DPC) applications.
Launching in March, SOQEL A2 sets a new benchmark for fire safety and durability in external wall insulation. It’s the first fully fire-tested system for below DPC applications, meeting the latest A2-s1,d0 fire classification required for materials in buildings over 11m. This ensures compliance with the UK Building Regulations and provides a solid solution for the construction industry.
With UK building regulations now requiring that materials used in buildings over 11m must meet a minimum A2-s1,d0 fire rating, SOQEL A2 offers architects, contractors and specifiers a reliable solution in line with these regulations. Designed for use in below DPC areas, as well as balconies, walkways and plant rooms, the system improves fire resistance, impact protection and long-term moisture
“The UK offsite manufacturing sector is at a critical crossroads,” says Fareita Udoh, Industry Advisor, BOS. “Recent high-profile market exits have highlighted the fragility of the sector's production capacity, and the risks associated with inconsistent demand cycles. To address this, the industry must pivot toward a more collaborative, resilient model — and the “Unlocking Downtime in Offsite Manufacturing” survey marks a pivotal first step in achieving this goal.
Despite the potential for offsite to revolutionise UK housing and infrastructure delivery, the sector faces recurring challenges:
• Cyclical demand creates gaps in production pipelines, leading to downtime and increased fixed overheads.
• Supply chain disruptions and labour shortages further compound these issues, leaving manufacturers unable to operate at full capacity.
• Market exits have exposed the financial vulnerability of offsite manufacturers, where idle production lines and operational inefficiencies threaten business sustainability.
Without a strategic response, these challenges will continue to undermine the sector’s ability to scale, attract investment, and deliver the promised benefits of offsite construction — including faster build times, cost savings, and reduced carbon footprints.
The survey is a vital first step in a broader initiative to create a framework for collaborative ‘sprints’ – a strategy that would allow manufacturers to fill downtime with smaller or more flexible projects.
It will gather critical baseline data on production capacity, downtime patterns, and interest in a collaborative marketplace.
The data gathered from this survey will directly shape the structure of the planned workshop series, which will bring together manufacturers across the panelised, light gauge steel (LGS), and timber/hybrid sectors. A key objective of the project is to make the case for government backing – whether through grants, tax incentives, or investment in a national capacity-sharing marketplace. The ‘Downtime Sprint Framework will provide a clear, actionable roadmap for securing this support and driving sector-wide adoption.
“This is not just another industry study — it’s a strategic initiative with the potential to reshape the UK offsite market, adds Fareita. “The success of this initiative depends on engagement from across the UK offsite sector. By completing the survey and participating in the workshops, manufacturers, developers, and policymakers can collectively build a more resilient and efficient offsite construction ecosystem. This is an opportunity to not only address the challenges of underutilised capacity – but to unlock a new era of collaboration, innovation, and growth for the entire UK MMC sector.
You can take the survey here: https://bit.ly/4cCVod1
Source: www.buildoffsite.com
durability. Unlike traditional solutions, such as bitumen paint, SOQEL A2 delivers a more effective and resilient alternative.
The system integrates Coverrock x-2 pre-coated insulation, which ensures a strong and durable bond for coatings while protecting the A1-rated Stone Wool core during installation. Paired with Heck K+A SL coating and Heck CER Mesh, it also provides superior impact and moisture resistance, withstanding harsh weather and high foot traffic in exposed areas like balconies and plant rooms.
SOQEL A2 incorporates Heck 4S Silicone Render, ensuring a seamless finish that matches the overall façade system. Unlike traditional below DPC treatments, which may disrupt the building's
aesthetics, it offers a modern, integrated look while maintaining full regulatory compliance.
Joe Ragdale, Technical Director at Wetherby Wall Systems said: “We have worked alongside our ROCKWOOL Group sister company, HECK in Germany to launch this innovative system into the UK market. We are delighted to introduce SOQEL A2, the first system of its kind for below DPC and base areas. This solution provides architects and contractors working on remediation projects with a compliant, durable, and efficient way to enhance building safety while ensuring a seamless finish alongside insulated façade systems.”
Source: www.wall-systems.co.uk
S Jones Containers Secures New Modular Contracts
Modular building provider, S Jones Modular Buildings – part of S Jones Containers – has secured contracts worth a combined £160,000 to provide additional facilities for a school, a nursery and Hinkley Point nuclear plant, all set to be delivered within the next few months.
The team is currently preparing to start works on-site at Hedingham School and Sixth Form secondary school in Essex where three units will be used to form two separate buildings, and at the Grow Learn Play Project CIC in Banbury where the team is creating a new facility for nursery children. The new nursery unit is designed with a fire rating of REI 30 meaning its structural integrity will resist fire for at least 30 minutes to allow safe evacuation. It is also fully insulated and complete with flooring, LED lighting and two WCs. With installation by S Jones Modular’s site team expected to take around two weeks after delivery to each site, both new units will be ready to use after the Easter break.
After successful completion of a previous project for Arabelle Solutions at Hinkley Point C, S Jones Modular Buildings is returning to the plant this year and is on track to deliver a new site office, comprising two modular units. The external wall and roof of the new office will be spray-painted to a light grey
shade and the internal structure will be fully insulated, fitted with air conditioning and fire rated to REI 30 throughout. Given the nature of the site at Hinkley Point C, all Risk Assessment and Method Statements (RAMS) for the installation of the units must be completed within the site’s own procedures and following strict protocol.
S Jones Containers has also delivered a stunning new two storey, glass fronted hospitality suite for Hednesford Town Football Club in Staffordshire. The bespoke offsite building used 20 individual 20ft modular units stacked to provide a light and modern two-storey 576sq m facility complete with covered balcony overlooking the pitch. The front face of the building features full height glazed units, ensuring a clear, uninterrupted view of the pitch. The top level includes a covered balcony area, offering a unique vantage point for matchdays. Designed with an internal staircase, toilet facilities, a kitchen, and
contemporary anthracite grey exteriors, the building delivers a modern and functional workspace.
Simon Willis, Business Development Manager for S Jones Modular Buildings commented: “This eclectic mix of projects demonstrates the versatility and efficiency of our modular solutions. Each project we deliver is tailored to the specific needs of the client - we’re able to create bespoke facilities to serve a diverse range of sectors from education to energy and everything in between. Our dedicated project team co-ordinates the whole process including design and the logistics around each on site installation. Our in-house engineers work closely with clients to create modular buildings that meet the exact brief to provide the space they need quickly and efficiently.”
NBS’ latest sustainability survey reveals two-thirds of architects say sustainability is often sidelined in strategy and briefing stages. Despite some progress in sustainability practices within the construction industry, a significant gap remains in how early sustainability decisions are integrated into projects.
The landscape is rapidly changing as the demand for sustainable construction continues to grow, with professionals and clients leading the charge. Although regulation is increasing, it is still not enough to drive widespread uptake. The demand is primarily coming from industry professionals and clients, who are pushing for low-carbon projects that prioritise energy and resource efficiency, while also minimising waste in both buildings and infrastructure.
These evolving requirements underscore the urgent need for the industry to address sustainability concerns from the earliest stages of project planning and throughout the entire construction lifecycle. Despite this progress, the concept of circular construction is still very much in its infancy, highlighting the need for further development and integration of sustainable practices across the sector.
Compared to the last NBS Sustainable Futures Report in 2021, there has been a 10% increase in respondents stating that sustainability is “usually or always” achieved on their projects, rising to 43%. For architects specifically, the figure is 35%. However, a third of professionals also reported that their projects rarely or never meet these sustainability goals, indicating substantial room for improvement.
While the majority of respondents (72%) say sustainability is typically considered during the design stage, 84% agree it should ideally be addressed much earlier - during the strategy and brief stage. This early intervention would set clear sustainability goals,
establish appropriate budgets, and ensure effective outcomes throughout the project lifecycle.
There’s a notable disconnect between when sustainability is typically considered in practice (the design stage) and when it should ideally be addressed (strategy and brief). Architects and engineers are calling for a more integrated approach to sustainability from the outset, with 62% of respondents with these job roles agreeing that sustainability should be considered during the strategy and brief stages. This gap highlights the lack of regulatory force driving earlier integration of sustainability into projects. Increased regulation would help address this issue, ensuring that sustainability is prioritised at the earliest stages.
Dr. Lee Jones, Head of Sustainability at NBS, said: “The construction industry is making incremental but important strides toward reducing its environmental impact, with NBS reporting a positive uptick in the percentage of projects where sustainability is 'usually or always' achieved. This progress signals a growing commitment within the sector, though it’s clear that we still have significant work ahead of us to fully integrate sustainable practices throughout the lifecycle of projects.
“But looking ahead, there’s a strong need for the industry to adopt sustainability at the very beginning of the process, during the strategy and brief stages. The fact that so many professionals agree that sustainability should be addressed earlier is promising, but the gap between intention and practice remains. Only by embedding sustainability from the very start, as outlined by frameworks like the RIBA Plan of Work, can we ensure that the buildings and infrastructure of tomorrow will truly meet the environmental and social challenges of the future."
Source: www.thenbs.com
GypLyner Xternal Offers Infill System for Multi-Storey Buildings
Intrastack, in conjunction with British Gypsum and Isover is offering GypLyner Xternal, a complete Saint-Gobain through-wall system now available for use with its steel structural framing system (SFS). Delivering fire and thermal performance for multi-storey projects, this complete, tested infill solution simplifies the route to specification with all components from Saint-Gobain.
All plasterboard, light gauge steel frame, insulation and sheathing board are supplied as one infill system, which, when constructed together, can provide the primary fire resistance and weather tightness of the external wall. GypLyner Xternal is covered by the Saint-Gobain full system warranty combining SpecSure® Warranty and Intrastack design-life up to 250-years - assumed first maintenance at 60 years, and that building purpose and/or its required performance does not differ from which the Intrastack SFS was first designed.
Specifying as a complete system means that performance data evidence how all of the components work together. This gives customers confidence at design stage that if assembled correctly, the building will perform as designed. For example, GypLyner Xternal provides thermal performance through a range of insulation solutions. Fire testing delivers fire resistance to BS-EN 1364-1 for 60, 90 and 120 minutes. The non-loadbearing SFS infill system comprises a 20mm deflection head with one layer of Glasroc X Sheathing Board to the external side and two layers of Gyproc SoundBloc 15mm to the internal side of 100mm of Intrastack SFS framework. 50mm of Isover Acoustic Partition Roll (APR 1200) is used in the cavity.
Andy Higson, Business Director at Intrastack added: "On busy multi-storey construction projects, our customers need time-saving solutions that do not compromise on performance. The GypLyner Xternal through-wall system is now available with our Intrastack Steel Framing SFS components to help deliver the certainty required. This includes thermal and fire performance that meets current guidelines, backed with full supply-chain traceability.”
Source: www.intrastack.co.uk
Our end-to-end construction solution brings together development, design, construction and funding expertise for healthcare projects throughout the UK. We offer a full-service package from project conception to completion - and our commitment to you doesn't just end when construction does.
CONSULT CONSTRUCT MAINTAIN
After your facility is up and running, the same team remains your first point of contact for ongoing training and maintenance. We understand that construction projects can be complex, and that's why we're dedicated to offering a reliable, approachable and friendly aftercare service.
We're not just building healthcare facilities; we're building relationships. And we’re committed to our clients every step of the way.
East Suffolk and North Essex NHS Foundation Trust
University Hospitals Plymouth NHS Trust
UK INDUSTRY NEWS
TALO Awarded 8-Unit Offsite Housing Contract
TALO has been awarded its first contract for Frankham Developments. The scheme at Oregon Square in Orpington, Kent will provide eight ultra-low energy homes for market sale in a new landscaped cul-de-sac. The development comprises four semidetached two-bedroom properties and four detached three-bedroom houses. The chalet-style homes are architecturally designed to a high standard in keeping with the residential area and to meet the stringent design requirements of the London Plan.
TALO’s advanced timber superstructure system will be manufactured offsite in Finland to reduce work on-site, deliver a higher level of thermal efficiency and to ensure the homes exceed Passivhaus energy standards. This will give homeowners the benefit of
ZED PODS Gains
ZED PODS has been awarded the prestigious ICW Endorsed accreditation. This recognition marks a significant milestone in ZED PODS’ continued growth across the UK. The ICW Endorsed accreditation follows a rigorous technical assessment of ZED PODS’ built system, ensuring it meets ICW’s stringent technical requirements.
much lower running costs and greater certainty of delivery on time and on budget for Frankham. The structures are due to arrive on-site in the summer and each home will take just one week to build ready for fitting out and installation of brickwork, render, timber cladding, and roof tiling.
Commenting on the specification of TALO’s offsite system for this project, Oliver Morse, Director of Frankham Developments said: “We have seen many offsite and MMC solutions at Frankham and have found this to be the best in terms of quality of build. The biggest benefit of the TALO approach for us is programme certainty and how this system can minimise the impact of the British weather. Rain can cause quality issues, delays on-site and make it very
ICW is one of the UK’s leading providers of building warranties and building control services. ICW Endorsed is a bespoke accreditation scheme for Modern Methods of Construction (MMC) systems for use in conjunction with ICW structural warranties and is used exclusively for systems that meet the requirements of ICW for structural warranty purposes.
As one of the UK’s largest structural insurance warranty providers, ICW serves all major mortgage lenders. This endorsement means that ZED PODS’ modular builds are now approved, subject to satisfactory site audits, for use in conjunction with ICW’s structural warranties.
ZED PODS has a strong track record of delivering sustainable, high-quality modular housing solutions on urban land parcels and brownfield sites. The company has previously collaborated with ICW to provide structural warranties for several housing projects, including the innovative Fortis House social housing scheme in Kent. This development, delivered in partnership with Ashford Borough Council, provides low carbon move on accommodation provision for
difficult to schedule the internal fitout phases, which can then add cost and programme delays. “Another major benefit is that we can replicate the design of the structure and roll it out on to other sites with cost certainty and reduced design fees. We also anticipate that the much lower energy costs for each home will be an important selling point in a competitive housing market.”
Bengt Magnussen, Commercial Director of TALO added: “Frankham has an established reputation for creating bespoke, high quality private residentialled developments, as well as being a development partner of choice for a number of housing associations in the Southeast of England. We are delighted to be awarded our first project with their team and are looking forward to demonstrating how we can facilitate the delivery of ultra-low energy homes on time and to the highest possible build standards.
“Our approach to offsite construction and MMC gives our customers unrivalled flexibility in architectural design for low rise housing. Our dry timber processes from sawmill and factory to site mean our timber structural installations are completely watertight and airtight in a matter of days. This reduces movement and snagging and improves the thermal efficiency and airtightness of every home we build.”
The properties at Oregon Square will have brick cladding, render, pitched roofs and dormer windows to reflect the character of the residential area. Each home will have a dedicated cycle store, generous rear garden and a front parking space. The chalet bungalows will be wheelchair accessible. The delivery architects for this project are Gebhard and Goodwin and the principal contractor is Building Associates.
Source: www.talo.co.uk
households seeking permanent housing solutions. The 23 apartments have been built on a 2.4m high steel podium on an underutilised car park located in Flood Zone 3A.
“We are delighted to receive ICW Endorsed accreditation, which further validates our commitment to delivering high-quality, sustainable modular homes,” said Thomas Northway, Chairman, at ZED PODS. “This endorsement strengthens our position in the market and ensures that our homes continue to meet the highest standards of quality and compliance.”
Andrew Spratt, Managing Director of ICW Insurance Services, added: “ICW is proud to support innovative companies like ZED PODS that are leading the way in high quality sustainable construction. Their successful track record, including the Fortis House project, demonstrates their ability to deliver exceptional modular housing that meet our stringent technical requirements for structural warranties, and we look forward to supporting their continued growth."
Source: www.zedpods.com
UK INDUSTRY NEWS
Foxford School Chooses Thurston Group for Offsite Classrooms
Thurston Group is set to deliver a full turnkey solution for additional classrooms at Foxford School & Community Arts College in Coventry. The manufacture and installation began in November 2024 and will be completed by June 2025.
Funded by Coventry City Council, the project will involve the manufacturing and installation of four new bespoke offsite manufactured facilities including additional classrooms, cloak rooms and office space, designed to accommodate the school’s growing student population and provide a modern and inspiring learning environment.
It will see the school provided with additional classrooms and toilet facilities, with flexible spaces to accommodate various teaching needs. The new classrooms will house an additional 120 pupils, along with four extra teachers and two teaching assistants.
Speaking about the project, Councillor Dr Kindy Sandhu, Cabinet Member for Education and Skills said: “We want every child in Coventry to have access to the best education. So, the opening of these new teaching facilities is not just great news for the staff and students at Foxford, it is great news for Coventry, as the young people who study in these classrooms will have the foundations to take our city forward.”
CITB Publishes 2025-26 Business Plan
The Construction Industry Training Board (CITB) has launched its Business Plan for 2025-26, outlining the practical steps it will take to support the construction industry in recruiting, training, and retaining a competent and skilled workforce.
The Business Plan aligns with CITB’s recently published Strategic Plan 2025-29, which was developed following extensive consultation with construction employers, training providers, national Governments, and other key stakeholders. This Business Plan sets out how CITB will address the skills and training challenges facing the construction industry in 2025-26 and sets out three key pillars to address the top priorities the construction industry wants CITB to focus on: getting more trained people into industry; making sure good quality, relevant training is available at the right time and place; and improving the skills of the current workforce.
To support these pillars, CITB is investing over £15million in its National Construction College (NCC) to expand training provision across its three sites. This investment will increase the range and volume of apprenticeship and commercial training opportunities,
The offsite approach will minimise disruption to the school’s daily operations, allowing the structure to be built and installed rapidly without interfering with ongoing curriculum activities. Throughout the install process, Thurston provided opportunities for students at the school to tour the site, giving them an insight into offsite manufacturing as a potential future career path.
Speaking about Foxford School, John Pay, Thurston Group Sales & Marketing Director said: “This project is further evidence of the power of offsite manufacturing, allowing us to deliver durable, modern and cost-effective educational spaces within just three months, we will be able to provide the school with new, high-quality facilities that will greatly benefit the students and staff. This project exemplifies the speed, efficiency and reliability of off-site construction.”
Thurston Group also recently appointed a new Production Director. Dan Pollard brings with him over 25 years of experience working in the modular manufacturing industry, having managed complex,
large-scale modular construction projects, across the world, from the UAE to Armenia, as well as the UK and Ireland. In his new role, Pollard is taking full ownership of manufacturing facilities to drive efficiency and elevate the quality of modular solutions.
Speaking about his new role, Pollard said: “My focus is on driving greater efficiency through increased productivity, smarter use of technology, and waste reduction. My global experience in the modular construction industry will support the continued scaling of our operations, enhancing both our manufacturing capabilities and the solutions we deliver across a wide range of sectors.”
Matt Goff, Managing Director at Thurston, added: “We’re delighted to welcome Dan to Thurston. His exceptional track record in leading high-performing production teams and driving process optimisation brings valuable global insight that will strengthen our position at the forefront of modular construction.”
Source: www.thurstongroup.co.uk
with a focus on sustainability and improving the learner experience. NCC will continue to deliver highquality teaching and support, maintaining its role as a key provider of construction training.
Tim Balcon, CEO of CITB, said: “The success of the British construction industry impacts everyone, and its vital construction employers are well supported with their training and skills needs. To thrive, the industry needs the right skills at the right time. Our Strategic Plan 2025-29, which we launched earlier this year, sets out how CITB will support employers to recruit,
train, and retain the workforce they need, now and in the future.
“This Business Plan brings that strategy to life, outlining the practical steps we will take to support employers. I am looking forward to delivering this Business Plan, marking the first year of our Strategic Plan, and supporting more employers and workers in gaining the skills they need to drive Britain’s built environment forward."
Source: www.citb.co.uk
UK INDUSTRY NEWS
Stelling Announce Southampton Student Living Development
A landmark student living scheme will be built using modular construction at 119 High Street in Southampton. The £20million project will provide 257 studios, doubling the scale of Stelling’s previous developments to meet demand from the growing student population in the city. It will also be the developer’s most sustainable and energy efficient student facility, with a host of environmental features.
Located in the Old Town Quarter, within a conservation area and close to several listed, historic buildings, the project has been sensitively designed by Stelling’s inhouse architectural team to enhance the cityscape. It will replace two outdated 1960s commercial buildings and will deliver a range of high-quality student accommodation options in three blocks, from three to six storeys high.
This latest scheme follows Stelling’s multi awardwinning Bargate House (pictured) – also in Southampton, which regenerated and transformed a derelict site on the High Street.
As with Bargate House, the new student complex at 119 High Street will be operated by leading student living provider Unilife. It will feature a mix of one- and two-bed studios of varying sizes, including some apartment clusters with communal kitchens.
The high-specification private living spaces will be complemented by extensive shared amenities to encourage social interaction and enhance the student experience. These will include a gym, study areas, lounge spaces, gourmet dining room, karaoke room, meeting hub with coffee station, individual meeting rooms, games room, and laundry.
José Ignacio Alvarez, Founder and Executive Chair of Stelling Properties, said: “This project is a major milestone for Stelling Properties. It will be our largest modular student development to date and our most sustainable, being close to net zero and targeting a BREEAM excellent rating. Our use of advanced offsite manufacturing technology allows us to fully fit out and furnish each studio in our Hampshire factory. This will radically reduce the build programme and disruption during construction and will ensure earlier occupation for students in need of quality accommodation.”
Demolition works have just started on-site and preparation is now underway for archaeological excavations. A concrete podium will be constructed at ground floor level to accommodate the shared social amenities. A total of 263 steel-framed modules will be manufactured and craned into position for the private living space by Spring 2026. The development will welcome its first students in September 2026 for the start of the new academic year.
In another innovation, Stelling will install the façade finishes offsite in its factory, reducing work on site even further and demonstrating another advancement in its offsite construction solutions. The exterior of the scheme has been sensitively designed to suit its context, with light stone-effect cladding and red brickwork, and in keeping with the surrounding historic and listed buildings.
Richard Powell, COO of Unilife, said: “Our partnership with Stelling Properties continues to push the boundaries of what’s possible with modular technology to build student living accommodation of the highest standards, more efficiently. The design of 119 High Street has been shaped by extensive feedback and collaboration with our student community, ensuring we continue to meet evolving expectations for privacy, comfort, and social integration.”
“This use of offsite construction also allows us to refine our interior design themes and technological solutions in real-time before full-scale production, which is game-changing. Smart phone access technology will provide seamless, keyless entry, while mood lighting will allow students to set the perfect ambience in their private space.”
Source: www.stellingproperties.com
Built on Tradition, Driven by Innovation
Since 1792
In response to the growing demand for enhanced thermal performance in modular and high-rise structures, Don & Low presents Proshield®. This self-adhesive, vapour permeable and airtight membrane is designed for walls, floors and roofs, with its advanced properties ensuring a fully airtight building envelope.
Offering high tensile strength and effortless installation, Proshield® is also available in custom prints tailored to your business needs.
Airtight, the Peel & Stick Way!
UK INDUSTRY NEWS
Weston Group Launch BTR Division
Weston Group recently announced the launch of Weston Partnerships, a new division that is part of the group’s expansion strategy to foster development partnerships and joint ventures for funds managing Build-to-Rent (BTR) portfolios, local authorities, Ministry of Defence (MoD) site disposals and businesses who need MMC building components for their housing delivery. These businesses include later living housebuilders, student accommodation providers, local builders and contractors.
In addition to its existing affordable housing programme and market sale activities via Weston Homes, this new strategic expansion will leverage Weston Group’s varied new build, conversion and build-off-site expertise including subsidiary British Offsite’s MMC construction factory facilities and products to deliver high-quality, sustainable housing solutions at scale.
Weston Partnerships is led by Steve Hatton, Development Director, working closely alongside Peter Gore, CEO of Weston Group and Bob Weston, Chairman of Weston Group, overseeing the new division’s business growth and operations. As part of its initial pipeline, Weston Partnerships has already established key partnerships in the various sectors being focused on for business expansion.
Solohaus for CHESS Charity
The Hill Group has handed over 24 DuoHaus homes to Chelmsford charity CHESS Homeless. The modular, self-contained properties have been purpose-built to support local homeless people to regain stability and independence. Delivered by Hill in March 2025, the homes will be run by CHESS, with the charity providing 24-hour on-site assistance and support with living skills.
The DuoHaus homes, now ready for occupancy, were officially opened on 9 April, 2025, with a celebratory event attended by the Lord Lieutenant of Essex, The Mayor of Chelmsford and the CEO of Homeless Link, alongside representatives of The Hill Group, CHESS Homeless and other individuals and organisations that have contributed to making this milestone a reality.
Dick Maddon, Chair of the Trustees at CHESS, said: “Having 24 brand-new, fit-for-purpose homes will play a key role in opening doors to independence for those who have found themselves homeless in Chelmsford. Known as the Turning Point Project, the properties will offer a significantly improved living style for adults who have been homeless, with support from staff to help them move forward purposefully.”
Weston Partnerships is also working with retirement housebuilders, local developers and contractors needing MMC building components, provided by the Group’s subsidiary British Offsite. The deals include a collaboration with Elkins Construction across three developments using British Offsite’s innovative UniSystemLB product.
Steve Hatton, Development Director of Weston Partnerships, said: “I am delighted to lead Weston Partnerships which is part of the group’s expansion into the Build-to-Rent, Local Authority Housing, retirement and student accommodation sectors, amongst other parts of the housing industry. Our priority is to work closely with our partners to help accelerate housing delivery, improve affordability, drive MMC innovation and uphold the highest construction standards. Through this expansion we are well positioned to make a meaningful impact on the future delivery of housing.”
Peter Gore, CEO of Weston Group says: “Whilst the group will continue to operate within the Build-toSell sector via our core Weston Homes division, the housebuilding industry has changed dramatically over the last few years, and it is important for us to expand and create new income streams for the business. The Build-to-Rent, local authority and some of the other deals we have already secured have the advantage of being forward funded providing an upfront income stream which is highly advantageous for our cash flow and financial strength.”
Bob Weston, Chairman of Weston Group adds: “By harnessing our industry experience and British Offsite’s advanced construction technology, we can build more efficiently and at greater scale. This initiative reinforces our dedication to delivering sustainable communities while strengthening our partnerships across the housing sector.”
The 24 DuoHaus homes will be stacked on two levels, occupying the site of a former, obsolete motel building. Designed to have a 60-year lifespan, the homes are built to Future Homes Standards, exceeding building regulations for energy efficiency and sound insulation. Each DuoHaus provides a fully furnished and equipped home, complete with a fitted kitchen, white goods and all the essentials for daily life.
Rick Henderson, CEO of Homeless Link added: “The new DuoHaus properties in Essex provide comfortable homes that afford residents the space to regain their independence with on-site life skills support. They are an excellent stepping stone
from homelessness to a more permanent, settled lifestyle for some of the county’s most vulnerable residents.” The DuoHaus homes were born through The Hill Group’s desire to help those experiencing homelessness. Their low-cost, modular design – part of Hill’s broader SoloHaus initiative – has enabled Hill to deliver similar properties in a range of UK locations over the past six years.
L-R Hill Regional Director Rob Jack, High Sheriff
Julie Fosh, CHESS CEO Rob Saggs, CHESS Chair of Trustees Dick Madden, Lord Lieutenant of EssexMrs Jennifer Tolhurst, Mr Philip Tolhurst.
Source: www.solohaus.co.uk
UK
Merit Group Paint Positive Financials
Merit Group, one of UK’s leading industrialised construction and digital manufacturing specialists, has announced a strong set of financial results for the year ending 30 June 2024, underpinned by continued innovation, project delivery excellence and a bold investment in people, leadership and sustainability.
According to the Group Financial Results, year ending 30 June 2024, consolidated revenues ran at £79,758,079 with a gross profit of £16,116,790 and pre-tax profit: £5,774,209 with over 50 new employees taken on.
Operating at the forefront of offsite construction, Merit designs and delivers technically complex, sustainable buildings at unprecedented speed –completing facilities in a third of the time required by traditional methods. This is achieved through Merit’s vertically integrated model and its use of high PreManufactured Value (PMV) solutions, ranging from 75%–95%.
The results for Merit Group reflect a planned change in the way the business accounts for the use of its intellectual property (IP) and platform. Previously, profits from subsidiaries were transferred via
dividends to support central group services, including investment in innovation and the Group’s growing IP portfolio.
Given the volume of patents, technical know-how and proprietary systems now held at Group level, Merit has implemented a licensing model whereby each subsidiary—Merit Holdings and Merit Health—is charged a licence fee for use of this IP. This shift better reflects the true commercial value of the platform and is in line with Merit’s international growth plans, enabling future overseas entities to be structured under transfer pricing regulations and benefit from Patent Box tax relief where applicable.
Tony Wells, CEO at Merit, said: “This year’s financial results reflect the enormous talent, drive and ingenuity within our team. We’re building more than just facilities – we’re building a new future for how complex infrastructure is delivered, faster, better and more sustainably. Our commitment to nurturing future leaders through apprenticeships and graduate opportunities, increasing female representation and investing in strong leadership means we’re not only growing in scale but in resilience and expertise too. Looking ahead, the strength of our project pipeline reaffirms our dedication to advancing offsite
manufacturing and cutting-edge technologies, allowing us to expand our impact across multiple sectors. We are excited about the future and remain focused on delivering exceptional value to our customers.”
During the financial year, Merit continued to push boundaries in offsite construction, with significant project completions and new wins across healthcare and life sciences, including the completion of Moderna’s Clinical Laboratories at Harwell Campus - supporting the UK’s strategic vaccine research capabilities and the delivery of the Solihull Elective Hub, a state-of-the-art theatre block enhancing elective procedures for the NHS.
Merit also launched its UltraPOD® SFS Variant, a cost-effective, rapid-delivery solution for urgent healthcare needs, manufactured at its advanced facility in Cramlington using the latest roll former and panel line technology.
Image: L-R Kirsty Wells, Merit Chair and Tony Wells, Merit CEO
Source: www.merit.co.uk
OFFSITE OPINION
Published fortnightly, OFFSITE OPINION seeks out the thoughts and views from key personalities within the offsite world – from those making things happen in the factory environment and on-site – to all those thoughtleaders and board level decision makers. It captures the key conversations of those behind shaping the future of the built environment.
March/April proved to be dynamic and thought-provoking months for the offsite construction sector, with a series of insightful commentaries that reflect both the progress and the ongoing challenges facing the industry. From advances in light steel frame to the increasing importance of trust and collaboration, these five opinion pieces collectively presented a picture of an industry in flux.
WHAT HAVE BEEN OUR RECENT TOP 5 POPULAR READS?
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LIGHT STEEL FRAME TAKES CENTRE STAGE
Ben Towe, Managing Director of Hadley Group, made a compelling case for light steel frame as a cornerstone of the future construction landscape.
“As the sector searches for sustainable, efficient, and precision-driven alternatives to traditional construction materials, LSF offers a credible and commercially viable solution. It brings clear advantages in terms of adaptability, durability, and the ability to meet complex architectural requirements, while aligning with broader environmental goals. The carbon footprint of steel is also being steadily reduced thanks to innovations in production.”
Read in full here: www.offsitehub.co.uk/offsite-opinion-the-time-is-now-for-light-steel-frame
POLICY, COLLABORATION AND THE PUSH FOR SCALED HOUSING
Katie Rudin, Housing & Innovation Director at Akerlof, brought attention to the broader regulatory and financial landscape that underpins the adoption of offsite methods.
“With policy frameworks evolving and the public sector signalling stronger support for MMC, there is growing momentum behind industrialised construction. Yet, barriers remain. For offsite construction to truly scale, particularly in the housing sector, confidence from lenders, insurers, and the wider finance community must continue to build. Fragmentation in procurement, delivery models and supply chains continue to hinder progress, and closer collaboration between stakeholders will be essential.”
Oliver Novakovic, Technical and Innovation Director at Barratt Redrow, is a pivotal advocate for sustainable industrialisation in housebuilding.
“The housing sector is undergoing a transformative shift, with a growing emphasis on offsite construction. At the heart of this evolution are panelised systems, which have gained significant traction due to their ability to streamline the building process, maintain costs and overall quality. This shift is not just a passing trend – it is a fundamental change in how the industry approaches construction.”
Read in full here: www.offsitehub.co.uk/offsite-opinion-driving-innovation
BUILDING TRUST: THE CULTURAL IMPERATIVE
Trudi Sully, Director of Industrialised Design & Construction at Mott MacDonald, reminded us that human factors and the importance of trust is critical to offsite success.
“We know that collaborating reduces risk, especially during periods of innovation and change. We need to take more informed risks to take the next steps in accelerating transformation, and to do that we must have more trust in each other to work more effectively together. This is not about forsaking intellectual property or opening the doors to everyone. It is about identifying sticking points and finding ways to move forward more effectively.”
Read in full here: www.offsitehub.co.uk/offsite-opinion-trust-crucial-to-making-offsite-mainstream
BRIDGING THE DIGITAL GAP
Charlotte Garrett, Head of Industry Strategy at KOPE, offered a compelling analysis of the evolving role of digital technology within the offsite sector.
“Historically, investment in digital technology, particularly in the design phases, has primarily sat with architects, engineers and contractorled design teams, while the supply chain has often lagged behind. This disconnect compounds silos in the sector, limiting the ability of manufacturers to influence early-stage design decisions. To truly industrialise construction, we need to better enable the supply chain, ensuring that the logic of manufacturing is digitalised and connected to the design.”
Read in full here: www.offsitehub.co.uk/offsite-opinion-bridging-the-digital-gap
All these industry snapshots plus much more are published on www.offsitehub.co.uk OFFSITE OPINION is published every two weeks on LinkedIn via the Explore Offsite Page. Be sure to follow the page and subscribe to the newsletter to hear more about the latest views across the offsite industry and get them direct to your mailbox.
If you are interested in speaking to us for an upcoming Offsite Opinion get in touch with Harry Wright email: harry.wright@radar-media.co.uk
VOLUMETRIC VOICES –A WORKFORCE SPEAKS OUT
A new industry survey undertaken by offsite recruitment specialists ARV Solutions and leading offsite advisors Cogent Consulting, has revealed a range of views from staff recently involved with the volumetric modular housing sector.
The volumetric modular homes sector has seen a dramatic rise and fall over the last few years. The number of ‘disrupters’ entering the sector with huge delivery potential, deep financial backing and no end of technological know-how, made the prospect of delivering the timeworn target of building 300,000 UK homes a year within reach.
A mixture of factors has seen several of these companies fail – sometimes unexpectedly and due to external circumstances – but fail nonetheless, and exit to some financial tune, cancelled projects and significant job losses.
To pool opinion and try to understand the reasons why the volumetric modular homes sector has stalled in the way it has, ARV Solutions with
the help of offsite specialists Cogent Consulting, reached out to staff affected from several of the highprofile business that have closed to find out more and to try to undertake some root cause analysis, so that lessons can be learned and shared to potentially avoid repeat failures in the future when the technology trend inevitably re-emerges.
Overleaf you can read some (anonymous) comments alongside some handy graphics to explain some of the key themes and survey findings.
Although there has been an exodus of businesses from the volumetric homes sector, the survey revealed that whilst there is an air of trepidation from departing personnel about the factory environment they had been operating in, the overwhelming response was
that volumetric technology and the prospect of returning to work inside that industry were resoundingly positive – the way in which the businesses were structured, managed and ran perhaps less so.
But what are the perceived main reasons volumetric modular housing manufacturers have struggled in the UK? High initial set-up costs, overheated company growth and overly ambitious expectations, cash flow issues, supply chain immaturity/ disruptions, planning and regulatory frustrations, limited scalability and inconsistent demand pipelines. Put this together with fractured understanding and relationships between design and delivery teams plus the long-standing construction culture that is resistant to change, and the recipe is ripe for disaster.
EMPLOYMENT SURVEY
All these issues cannot be ignored. Indeed, one common complaint was a critical disconnect between trades within the manufacturing environment and the ‘site side’ of the construction project – delivery teams, installers and on-site processes. Clear communication is the bedrock of any successful construction project – using any building method in any sector. Only better training, education and collaboration can fix some of these problems.
“The voices of those who built and shaped the volumetric modular housing sector – only to be impacted by its closures – have largely gone unheard,” says Jim Roach, Managing Director of ARV Solutions.
“While much has been written about the industry's struggles, the skilled workforce deserves recognition. The response from our candidate network was overwhelming, demonstrating just how much this matters. I was alarmed by how many have left offsite construction, especially given the ongoing skills shortage. However, it is encouraging that most would return under the right conditions. The industry cannot afford to lose this talent – it must act to retain and attract these experienced professionals.”
The UK offsite sector contains many hugely talented and driven individuals and businesses, full of knowledge and expertise gathered over years – if not decades in some cases. This wealth of understanding is transferable to other sectors but also other countries. The UK offsite sector is well advanced compared to other parts of the world, and one thing that must not happen is for this level of experience to leave the UK in a ‘brain drain’ when construction and manufacturing skills at home are at a premium. Digital design with automated and robotic technologies, now sit alongside a wider understanding of supply chain management, product design and lean manufacturing processes.
“Re-engaging the volumetric modular technology supply-chain in residential developments will be essential in attempting to achieve government housebuilding targets,” adds Darren Richards, Cogent’s Managing Director. “This technology sits alongside
panellised and hybrid approaches and must be carefully selected and applied to the right projects if it is to be successfully delivered. The housing sector needs additional capacity from all offsite manufacturing resources available, and it is imperative that the volumetric modular sector dusts itself off, embraces the learnings from the recently challenging period and goes again.”
While the volumetric modular homes industry has taken a hit over the last three years, the technology and potential it holds is still huge. Market dynamics may have exposed weaknesses but there is still a compelling case – especially with affordable homes, where pattern book designs and a DfMA approach can unlock massive benefits and provide consistently high results – for it to play a transformative role in delivering the housing targets that successive Governments announce but historically fail to achieve.
For more information visit: www.arvsolutions.co.uk www.cogent-consulting.co.uk
Images: 01-03. The volumetric modular housing market has been volatile in recent years with several providers opening high-value facilities but ultimately failing through a variety of reasons
TRANSFORMING CONSTRUCTION
The UK’s only Industrialised Construction Conference and Exhibition is driving an industry-wide shift towards a more advanced approach to
EMPLOYMENT SURVEY
Over 50 people completed the ARV Solutions and Cogent Consulting Offsite Employment Survey, that took in comments from past employees of several businesses that have exited the offsite sector including: House by Urban Splash, Ideal Modular Homes, ilke Homes, L&G Modular Homes, Lighthouse, ModPods, M-AR, Swan NuLiving, Totally Modular and TopHat.
What was your job role?
“Modular housing has significant potential to address housing shortages, reduce construction timelines, and improve sustainability. To fully realise these benefits, manufacturers, policymakers, and the construction industry must work together to overcome challenges such as regulatory hurdles, market perception, and supply chain dependencies.”
Were you able to secure a new job within the modular/offsite sector after your previous employer ceased operations? How long did you work in volumetric modular housing?
“I
do you think you would return if opportunities improved?
“Failure to prove that offsite can be cheaper, faster and higher quality made getting a pipeline much harder over traditional builds and work dried up tipping companies who were already losing millions over the edge as the investors pulled out.”
“Quality product should come first, plus there should be a backbone of skilled trades and ancillary trades teaching the unskilled labour with effective training and ongoing education.” What key skills or knowledge did you gain in
Simplify the Product –Reduce Multiple Variants Employ More Skilled Trades
SOLVING THE HOUSING CRISIS –OFFSITE TO THE RESCUE
As housebuilders grapple with an increasingly volatile market, can offsite methods help get ‘Britain Building Again’ and boost capacity? Trevor Richards, Operations Director for offsite experts Cogent Consulting, explains how.
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The ongoing skills shortages, sharp fluctuations in material costs and the cost-of-living crisis are putting immense pressure on the housebuilding industry. The Chancellor declared in her Spring Budget, that the Government expects to ‘undershoot’ its manifesto target of 1.5 million homes in five years, estimating there will be fewer than 1.3 million cumulative net additions to the UK housing stock between now and March 2030.
Since the 1940s, net housing supply has only neared 250,000 homes per annum alongside a substantial social housebuilding programme - or with government intervention – the Help to Buy scheme between 2013 and 2022. We have not even got out of the starting blocks and after announcing significant investment to deliver 18,000 new social and affordable homes, the government is rowing back on its housing targets already.
Based on responses from 31 of the largest housebuilders, a report from the Home Builders Federation (HBF) found that 17,432 ‘Section 106’ affordable housing units with permission remained uncontracted in October 2024, with work on 139 building sites delayed – so will the
£2billion injection of investment announced on 25 March, be enough to get anywhere near the downgraded targets with such deep and divisive issues? The Section 106 situation shows we need creative thinking here to develop new financial models to encourage independent housebuilders to deliver much needed social and affordable homes at speed and scale.
Councils, local authorities and registered providers have to consider the significant role offsite construction (OSC) and offsite manufacturing (OSM) can play to overcome the traditional skills shortage and the housing crisis. To get anywhere near the 1.3 million downgraded target, I firmly believe increasing cost-efficiency, productivity and quality through offsite construction is crucial to success.
The need for speed
We all know that offsite construction enables homes to be built more quickly compared to traditional methods, as a significant portion of the work is done in a factory while groundwork is prepared on-site. This parallel working can cut construction time by up to 50%, allowing for the rapid delivery of housing developments. Speed is critical in
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addressing the UK’s pressing need for new homes, where shortages and high demand have driven up costs and created affordability issues. Given the UK’s urgent need for new housing, fast-tracking building programmes are crucial to meeting the government’s annual target.
Standardisation and scalability
Offsite manufacturing revolutionises the way we build homes, enabling the mass production of standardised housing elements that can be rapidly assembled on-site. This efficiency is further amplified by the use of pattern books, where pre-approved design templates take standardisation and scalability to another level.
Scalability is essential to meeting the government’s ambitious housing targets within the current five-year term. Offsite construction allows developers to rapidly increase output, especially in high-demand areas. In addition, consortium procurement is gaining traction as a powerful enabler. By fostering collaboration and pooling resources, this model strengthens supply chains, creates more predictable pipelines of work, and significantly enhances the capacity to scale.
INDUSTRY OPINION
Cost reduction and efficiency
By manufacturing building elements (panels, pods and modules) in a controlled environment, OSM can reduce waste and optimise the use of materials, leading to lower overall costs. This has the potential to make some housing projects more affordable and can help address the financial barriers that have limited the development of new housing, particularly in areas where land and labour costs are high. The ability to produce homes at a lower cost without compromising quality makes OSM an attractive solution to the UK housing crisis. As OSM becomes more widespread, economies of scale will further lower costs, helping to tackle the affordability issues that are central to the UK housing crisis. The standardised production process makes housing projects more predictable in terms of costs and timescales which is essential for delivering affordable housing.
COGENT CONSULTING
Consistency and quality
Factory-built elements are subject to rigorous quality control, ensuring that they meet a wide range of industry standards, regulations and requirements. This is especially important for large-scale housing projects where consistent quality can ensure building performance and reduce long-term maintenance costs. Creating buildings in a controlled factory environment with suitable controls provides a better opportunity for greater consistency and quality assurance, thereby positively reducing the number of defects or the need for repairs experienced on-site. This potential for consistently high build quality should also ensure that the expectation between design performance and as-built performance is much closer.
Environmental impact
Offsite construction promotes sustainable building practices by
Offering independent advice on exploiting innovative construction processes, Cogent Consulting is the leading multi-disciplinary consultancy specialising in the field of offsite construction and manufacturing. Its unparalleled range of skills can help manage the practical issues of developing and deploying offsite construction systems and processes to dramatically improve project delivery performance.
For more information visit www.cogent-consulting.co.uk or call 01743 290010
minimising on-site waste, reducing the carbon footprint associated with traditional construction, and enabling the use of eco-friendly materials and technologies can contribute to creating energy-efficient homes, aligning with the UK’s net zero carbon goals. With sustainability concerns becoming an increasingly important part of urban planning, OSM can help deliver homes that meet strict environmental standards while addressing the housing shortage.
Offsite methods and factory manufacture offer innovative, scalable, and sustainable solutions to address the UK housing crisis. They can deliver high-quality homes more quickly and efficiently than traditional methods, while also addressing affordability and quality concerns. But smart pipeline management is needed to create a better model for this all to work. By focusing on repeatable, standardised solutions, offsite construction can provide high quality housing for all facets of the UK population, help achieve housing targets and alleviate pressure in high demand areas.
Images: 01. Trevor Richards, Operations Director, Cogent Consulting 02-04. The housebuilding market and its buyers can benefit from offsite efficiency.
Courtesy British Offsite/Frameclad Lowfield Timber Frames 4 3
FAST-TRACK TO BETTER HEALTHCARE ESTATES
Expanding medical facilities is a challenge many healthcare services face, especially when time and budget constraints are significant, but as Wernick Buildings point out, modular design has huge potential to reduce these problems and offer a more efficient way to meet demand.
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Designed for flexibility and rapid deployment, modular structures provide high-quality, customisable spaces tailored to a wide range of medical needs. Whether you're planning a new ward, operating theatre, office space or a complete medical facility, a modular building could be the solution to support scale operations quickly while maintaining a high standard of care for patients.
Fast delivery of a modular building
The efficiency of a modular healthcare buildings lies in its ability to significantly reduce manufacturing and installation time, completing projects in nearly half the time of traditional methods. By producing modules in a controlled factory environment, delays are minimised while site groundwork progresses simultaneously. Once completed, modules are transported, craned into place, and assembled onsite, either side-by-side or stacked up to five modules high. This streamlined process enables healthcare facilities to scale quickly, meeting accommodation demands with speed and flexibility, ensuring vital services are operational without unnecessary delays.
Flexible systems are designed to deliver compliant healthcare spaces
Whatever your requirements, modular healthcare buildings can be tailored to
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meet the NHS's spatial and technical needs. Fully HBN and HTM-compliant spaces can be ready for fit-out in as little as 24 hours. From wards and theatres to waiting rooms and office spaces, modular systems offer the flexibility to scale and address critical demands.
In emergencies, modular buildings provide rapid, essential facilities such as intensive care units, isolation wards, and triage centres, enhancing patient care and operational efficiency. These spaces are designed for seamless integration and futureproofing, ensuring they meet both urgent and long-term requirements.
Modular theatres, staff rooms, and other facilities can be swiftly deployed with minimal disruption to healthcare services. Built to the highest standards in controlled environments, they meet healthcare regulations while remaining durable and cost-effective. Custom features, including rest areas and kitchenettes, support staff well-being, whilst implementing reductions in waste and operational costs due to the energy-efficient, sustainable designs.
Reduced disruption in your estate
Each modular healthcare building is meticulously designed and manufactured in a controlled factory
environment before being delivered to your site for seamless installation. With most of the construction happening offsite, noise, dust, and on-site activity are significantly minimised, ensuring nominal interference with daily operations. This efficient process is particularly beneficial in healthcare environments where maintaining a calm and uninterrupted atmosphere is essential. The streamlined installation ensures your facility can continue functioning as normal, with the added benefit of accelerated project timelines.
Why choose Wernick for your modular healthcare building?
At Wernick Buildings, we excel in designing and delivering permanent modular building solutions that combine advanced offsite construction with sustainable practices. Our systems enable swift project delivery while maintaining quality and fostering architectural creativity.
We specialise in healthcare solutions tailored to NHS requirements, including fully compliant modular wards delivered and ready for fit-out within 24 hours. Our hybrid approach integrates modular and traditional methods, providing cost-effective, high-quality facilities, all while adhering to rigorous standards. By leveraging modular construction, healthcare providers can minimise downtime, reduce disruption, and ensure that patients have access to state-of-the-art surgical facilities.
For more information visit: www.wernick.co.uk
Images: 01-02. A modular approach to the healthcare estate can deliver massive benefits in building design and delivery
LIGHT STEEL FRAME
FACTORY OPEN DAY SHOWCASES INNOVATION
Frameclad recently opened its doors to visitors and provided an exclusive opportunity to tour its facilities in Kingswinford to better understand offsite manufacture and one of the UK’s leading light steel frame providers.
Operating from two adjacent hightech manufacturing factories with a combined area of 50,000sq ft of factory and office space — including a dedicated 24,000sq ft framing facility — Frameclad held an ‘open day’ to host a wide range of construction professionals. Attendees included architects, structural engineers, contractors, and local authority regeneration teams. The event showcased how Frameclad is not only delivering cutting-edge light steel solutions but also earning praise for exceptional quality and unrivalled customer service.
Substantial investment in cold rollforming machinery – now seven machines – supported by customised Tekla software, produces both loadbearing and non-loadbearing light steel framing systems with huge interest in its Lightweight Engineered Adjustable Frame (LEAF) system.
Visitors were shown around both manufacturing facilities covering cold roll forming and the assembly factory by Operations Director, Paul
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Stefanovic, who outlined the steps taken to produce its infill solutions and complex loadbearing systems with the capability to go up to nine storeys. “The flexibility and type of profile – angles and ‘Zs’ – that we can produce, and supply is exceptional,” said Paul. “It means that we can deliver a much more flexible and betterquality product. In keeping with offsite manufacture generally, our ethos is to capture mistakes inside the factory rather than outside the building.”
Of huge interest was the LEAF system – something described as ‘simple but revolutionary in application’. Essentially the four-axis adjustable light steel frame infill system can be extended and aligned in all directions to overcome the challenges associated with mainframe dimensional discrepancies. The surrounding structure in which a frame is placed is not always aligned as intended, and it is important for frames to be as adaptable as possible to ‘fill’ the void.
LEAF is the result of the total Frameclad team – designers,
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engineers, manufacturers and technical experts – coming together to create a system that overcomes an issue that is frequently experienced once a light steel frame infill system arrives on-site. “What sets LEAF infill panels apart is that the system can be adjusted on-site in all directions with total ease,” said Nik Teagle, Joint Managing Director for Frameclad. “From ‘top to bottom and side to side’ without the use of any specialist tools, cutting or welding equipment. When the aperture is totally ‘infilled’ from ceiling to floor and wall to wall, the innovated light steel mechanism is just locked into place. Safeguarding our ‘fit first time’ ethos, LEAF offers installers the flexibility to compensate for dimensional issues. Ensuring that the aperture is totally infilled, improves airtightness within the building envelope to enhance thermal performance and help achieve net zero goals.”
LEAF is expected to have huge benefits for the retrofit sector where existing structures can be reconfigured, and an adjustable frame
LIGHT STEEL FRAME
system will help reduce costs, waste and the time taken on changing walls or room layouts. With zero waste in the manufacturing process and no cutting or welding on-site, the LEAF system has a predicted design life of 250 years in a warm frame environment.
With a 14 strong in-house design and engineering team that can provide cost estimates within 10 days and detailed designs within one week, customer service has been central to Frameclad’s on-going success. “We offer a significant level of site support as a manufacturer,” says Dale Joy, Frameclad’s Regional Specification Manager for the North. "We don't just send our products to site and leave.
For Frameclad, engagement begins well before the first tool is lifted. Our team often visit our client’s offices and sites prior to project kick-off, delivering tailored presentations to ensure site teams are fully familiar with every aspect of our system. This early engagement has a clear goal – to equip contractors and installers with the confidence and knowledge to build accurately and efficiently. From toolbox talks and drawing reviews to on-site collaboration and technical reports, Frameclad’s involvement is comprehensive.”
This hands-on, consultative approach is gaining traction — and attention. According to Dale, more main
WATCH OUT - PEELERS YARD, NEW CROSS, MANCHESTER
Being built on the site of an 1800s police station in one of Manchester’s latest neighbourhoods – the aptly named Peelers Yard is a new Build-to-Rent apartment complex. Transforming unloved spaces into vibrant places, the CERT development creates 81 contemporary open plan one- and two-bedroom apartments across eight floors together with duplex penthouses and townhouses. Designed by Tim Groom Architects and engineered by Ridge and Partners LLP, the scheme seamlessly brings together newbuild and historic elements.
“Frameclad has been appointed to design and manufacture our fully tested noncombustible steel framing system for the project,” says Dale Joy. “Our ability to be engaged early, and partner throughout the process is ideal for projects such as this. We are providing fully assembled and pre-boarded loadbearing panels along with the hot rolled ancillaries. This demonstrates the integration of an offsite mindset and DfMA whilst retaining the heritage of the existing site. We are also privileged to work alongside Big Red Construction Group supporting CERT Property.” In line with the developer’s sustainability ethos, the centrepiece of Peelers Yard is the former police station’s 25-metre chimney stack, which has been retained and will be adorned with a lantern.
Images: 01-05. The open day was a huge success with visitors seeing light steel frame in production and meeting the Frameclad team 5 3 4
contractors and developers are turning to Frameclad earlier in the design and planning stages. It’s a trend he attributes to the company’s proactive nature and its client-first mentality.
Backed by BOPAS accreditation, NHBC, Steel Construction Institute, Infill and CE certification, Frameclad has also invested in a growing suite of fire test and performance data to offer assurances that the system is robust and adheres to the new pressures created by the Future Homes Standard and Building Safety Act, with its golden thread of information and Gateway stages to ensure long-term reliability and structural integrity.
“We were delighted to invite the many industry professionals and local authority teams to see how our light steel frames are transforming the construction landscape,” added Nik Teagle. “Our systems are not only fast to install but also meet the highest safety and environmental standards, offering a durable and high-quality solution for modern building needs.”
For more information on how Frameclad can transform your project, you can visit the upgraded and freshly relaunched website: www.frameclad.com
CONSTRUCTION TO PRODUCTION
As a powerful catalyst for driving real-world transformative change, the UK’s only INDUSTRIALISED CONSTRUCTION CONFERENCE AND EXHIBITION, stands out as the premier platform for highlighting genuinely groundbreaking solutions and fostering high-impact collaboration towards delivering advanced construction methods.
02-03 JULY 2025 MTC, COVENTRY
The event will spotlight innovations that are making a difference now using next-generation digital technology, and will bring a wide range of industry leaders, policymakers and trailblazers together for bold and thought-provoking discussion on how to redefine the way we build.
INDUSTRIALISED CONSTRUCTION is creating a launchpad for change, revealing how cutting-edge digital tools and manufacturing technology are boosting much needed efficiency and productivity levels and radically streamlining building design and delivery.
The event will tackle the sector’s biggest challenges and show how Industry 4.0 technologies can also keep up with rapidly evolving building regulations and challenging market demands.
Designed to push the boundaries of what is possible in today’s construction industry, the INDUSTRIALISED CONSTRUCTION CONFERENCE is your front-row seat to hear about the groundbreaking technologies transforming the built environment. With an emphasis on unlocking the full potential of Industry 4.0, the conference will delve deep into the most pressing manufacturing and construction challenges and reveal the transformative solutions reshaping every aspect of the construction arena.
HAPPENING RIGHT NOW
Laying the foundations for a new era of construction, INDUSTRIALISED CONSTRUCTION is a forum where technology meets practical applications to leverage change that is already delivering transformational and measurable results acris the UK’s built environment.
INDUSTRY TRAILBLAZERS
PERSONAL DEVELOPMENT
Engage in dynamic, thought-provoking discussions with industry pioneers, academics and innovators who are pushing boundaries to bring about transformative change. Whether you are a seasoned construction professional, interested in technology, or just a newcomer exploring the field, the event will equip you with the knowledge and understanding to keep you ahead of the curve, network with key stakeholders and importantly connect with others in the fast-moving world of industrialised construction.
DEDICATED EXHIBITION
The co-located exhibition gives attendees an exclusive chance to engage directly with the people behind groundbreaking manufacturing technologies and digital tools. Speak face-to-face with those reshaping design, manufacturing, and the construction process. Find out more about how to boost efficiency, productivity, sustainability and cost-effectiveness. The exhibition lets attendees discover real-world solutions that are setting new industry benchmarks now and providing practical solutions to overcome challenges that have plagued the construction industry for decades. UNLOCKING POTENTIAL
The INDUSTRIALISED CONSTRUCTION CONFERENCE is a dynamic platform that brings together industry leaders, policymakers and trailblazers – empowering collaboration and knowledge-sharing at the highest level. The conference plays a pivotal role in driving industry transformation, ensuring that construction projects are not only more sustainable and efficient, but also capable of meeting the demands of a rapidly changing regulatory landscape and demanding marketplace.
HEADLINE SPONSORS
INDUSTRY PARTNERS
WORLD-CLASS SPEAKER LINE-UP
Learn from 30+ industry thought leaders, innovators and change-makers, including:
DAY ONE
INDUSTRIALISED CONSTRUCTION STRATEGY AND CONCEPTS
Andy Barnes - MTC
SESSION 1: UK Industrialised Construction Strategy
Mike Pitts - Innovate UK
Fergus Harradence - Dept. Bus. Trade
Ron Lang - CLC/AtkinsRéalis
SESSION 2: DfMA Approaches
Azim Jasat - Autodesk
Wolf Mangelsdorf - Buro Happold
Ben Carlisle - Mott MacDonald
Vaibhav Tyagi - Skanska
Eva Magnisali - Dataform Lab
SESSION 3: Pattern Books, Kit of Parts & Platform Design
Jamie Hillier - Akerlof
Richard Crosby - Seismic
Jaimie Johnson MBE - Bryden Wood
Neil Pennell - Land Securities
SESSION 4: International Perspectives on Industrialised Construction
Roland Sitzberger - Porsche Consulting
Jerker Lessing - Lessing Innovation
Daniel Hall - Tu Delft
Irfan Custovic - PhD Candidate - Tu Delft
02-03 JULY 2025
MTC, COVENTRY
DAY TWO
INDUSTRIALISED CONSTRUCTION IN PRACTICE
Keith Waller - HVM Catapult
SESSION 1: Healthcare
Tom Stocks - The New Hospital Programme – NHS England
Anne Daw - HLM Architects
Mark Griffin - NG Bailey
SESSION 2: Prisons and Infrastructure
Andrew Dewdney - Kier
Sam Ward - Laing O’Rourke
Dale Sinclair - WSP
SESSION 3: MOD and PBSA
Paul Ruddick - Reds10
Kieran Fields - FP McCann
SESSION 4: Residential
Ed Jezeph - Homes England
Helena Lidelow - VBC
Oliver Novakovic - Barratt Redrow
Shaun Weston - British Offsite
Ele George - Elevate
These are among the confirmed speakers providing expert commentary and opinion on how to embrace and accelerate advanced technology within a construction context and adopt a ‘construction to production’ approach to the built environment.
Join us and be part of the movement to change the future of construction in the UK and beyond.
For the full speaker line-up and to book your place, head to:
MARK FOR STEEL QUALITY
Certification and accreditation are critical elements of all building systems. Ben Towe, Managing Director of Hadley Group and head of the Light Steel Frame Association (LSFA), outlines how these impact the light steel frame sector.
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Here in the UK, businesses in the light steel frame (LSF) sector must pursue several key certifications and accreditations to comply with industry standards and regulatory requirements. These not only ensure product quality but also enhance a company’s credibility and competitiveness.
One of the most crucial certifications is BS EN 1090, which pertains to the execution of steel and aluminium structures. This standard ensures that the steel framing meets safety and performance criteria, with a mandatory CE marking required for construction products. The CE marking is vital for accessing the European market, ensuring compliance with safety and performance standards, and demonstrating commitment to quality.
ISO 9001, a quality management system certification, is another essential credential. It helps companies improve efficiency, reduce costs, and enhance customer satisfaction. By meeting the ISO 9001 requirements, businesses improve their operational effectiveness and boost their reputation with clients. Similarly, ISO 14001 focuses on environmental
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management, ensuring that companies minimise their environmental impact and comply with sustainability regulations.
Additional certifications, such as Constructionline, CHAS (Contractors Health and Safety Assessment Scheme), and BIM (Building Information Modelling) certification, are also valuable. UKAS accreditation, which applies to testing, inspection and certification bodies, is important because it verifies that a company’s products and services are independently tested against industry standards.
Challenges in accreditation and certification
The process of obtaining and maintaining certifications is not without its challenges. One of the primary hurdles is the complexity of standards and regulations. Different certifications often have varying criteria, documentation requirements and processes, which can be overwhelming for small businesses. This complexity can lead to confusion and delays in achieving certification, potentially resulting in non-compliance and costly setbacks.
Another challenge is the cost of obtaining certifications such as BS EN 1090 and ISO standards. Small and medium-sized enterprises (SMEs) may find these costs prohibitively expensive, diverting resources from other crucial business areas, like research and development. Additionally, once certifications are obtained, businesses must invest in ongoing compliance efforts, including training, audits and process updates. Failure to maintain compliance could result in the loss of certification and damage to a company's reputation.
Keeping up with the evolution of standards and regulations is also resource-intensive. As construction methods and technologies evolve, businesses must adapt to new materials and testing methods. Failure to do so can result in compliance gaps, legal risks and financial penalties. The entire accreditation process is time-consuming, requiring dedicated personnel to manage compliance efforts.
The role of digital tools in certification
Digital tools are becoming increasingly integral to the certification process in the LSF sector. Construction businesses are embracing digital transformation to streamline certification, testing, and compliance tracking. Digital platforms and software are used to manage documentation, track test results, and monitor audit reports in a centralised system. This digitisation improves accuracy, reduces errors, and makes compliance management more efficient.
The use of automated testing and quality control technologies, such as sensors, IoT devices and automated equipment, is also growing. These tools provide more accurate, consistent, and faster results during
CERTIFICATION AND ACCREDITATION
factory tests, reducing human error and speeding up the certification process. Additionally, BIM allows for the integration of all elements of construction, enabling better planning, collaboration and real-time access to project data. This digital platform can reduce the number of physical trials needed, improving efficiency and reducing costs.
The importance of fire safety certifications
Fire safety certifications play a vital role in ensuring the resilience of light steel frame systems. These certifications help ensure compliance with stringent building regulations, particularly in residential and commercial buildings. They validate that light steel frame systems meet fire safety requirements, such as fire resistance ratings, which determine how long a structure can withstand fire before failing.
Light steel frame systems are highly resistant to fire, but fire safety certifications ensure that they incorporate fire-resistant materials and coatings to maintain their integrity during a fire. For example, intumescent coatings, which expand when exposed to heat, create a protective layer that shields the steel frame. Fire performance testing is critical, ensuring that all components are tested for their fire resistance under real-world conditions.
Fire safety certifications also enhance structural resilience. Steel, though strong, can lose its structural integrity in high temperatures. Fire safety certifications ensure that appropriate measures, such as fire-resistant coatings, insulation, and barriers, are in place to protect the steel frame and prevent structural collapse. This is crucial for ensuring the safety of occupants and emergency responders in the event of a fire.
Impact of environmental risks on certification
When certifying light steel frame systems in regions prone to natural disasters like flooding, certification processes must adapt to address these specific risks. In flood-prone areas, light steel frame systems need to be designed to resist water damage and prevent structural collapse during flooding events. Certification criteria for such regions may require testing for water resistance, corrosion
resistance, and durability under prolonged exposure to moisture. In areas subject to storms or high winds, light steel frame systems must be designed to withstand uplift and lateral forces. Certification processes assess how well the frame resists wind pressures and ensure that components like roofs and walls are securely fastened to prevent damage.
Certification’s influence on innovation and flexibility
While some may argue that too many certifications can stifle creativity and flexibility, certifications actually support innovation within safety boundaries. They allow designers and engineers to experiment with new materials, construction methods and technologies while ensuring that these innovations meet required performance criteria, such as fire resistance and structural integrity. Light steel frame systems are known for their design flexibility, allowing for custom floor plans, open spaces and more efficient material use. Certification processes accommodate these design innovations by validating that nonstandard frame layouts or integrated systems, such as prefabricated walls, roofs, or entire modules meet safety and performance standards.
Misconceptions about certification in the LSF sector
There are several misconceptions about the accreditation process that can create confusion. One common misconception is that certifications are only about meeting minimum standards. In reality, certifications also validate a product’s quality, durability and performance in real-world conditions.
Another misconception is that certifications guarantee long-term performance. While certifications
ensure compliance with certain standards during testing, realworld factors such as environmental conditions can affect the system’s performance over time. Some believe that certifications are only necessary for large-scale projects, but residential projects also require certifications for safety, fire resistance, and energy efficiency.
Additionally, certification is not based solely on self-reported data – it involves third-party testing to ensure impartiality and accuracy. Lastly, not all light steel frame systems are the same – each system must be assessed individually based on its materials, design and intended use.
Advice for new businesses in the LSF sector
For small businesses entering the LSF sector, understanding the core regulatory requirements is essential. Start with basic certifications, such as fire safety and structural performance, and gradually expand as the business grows. Partnering with third-party testing agencies and using modular solutions can streamline the certification process. Additionally, developing a robust quality management system (QMS) and seeking advice from experienced partners or consultants can help new businesses navigate the certification process more effectively.
For more information visit: www.bsigroup.com www.ukas.com www.hadleygroup.com www.lsf-association.co.uk
Images:
01. Ben Towe, Managing Director of Hadley Group and head of the Light Steel Frame Association 02-03. Light steel frame systems are covered by a range of industry certifications and accreditations
CONNECTED WORKFLOWS FOR OFFSITE
Trimble’s Craig Johnson explores the value of connected construction for the offsite sector, with unique workflows that take manufacturers and contractors from the initial concept design right through to on-site assembly and snagging.
A golden thread of information is at the heart of modern-day construction, ensuring compliance with the evolving building regulations, including the Building Safety Act. As such, a common data environment and smooth flow of data throughout a project can be invaluable, connecting teams, software and construction stages.
Design and detailing
While many may associate Tekla Structures (Trimble’s 3D modelling & detailing software) with the offsite industry and its ability to combine different materials into one model, Trimble’s portfolio goes far beyond this. It provides offsite manufacturers and contractors with a complete and comprehensive workflow that connects all stages. From Sketchup for initial concept design and Tekla’s portfolio of products, which covers everything from design and detailing, estimation, production management of structures and now also mass timber; through to enhanced collaboration in Trimble Connect. Trimble also offers a comprehensive suite of products specifically for MEP, covering every step of the construction process.
For more information visit: www.trimble.com/en/industries/ construction 1
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Project management
When it comes to maintaining control of projects and the golden thread of data to support legislation around the Building Safety Act, Trimble offers two solutions. These are Viewpoint for Projects, a construction management software providing tools for project management and collaboration and Viewpoint Field View, a mobile and cloud-based solution tailored for construction field management. These systems allow construction teams to manage tasks, capture data and document projects onsite, using mobile devices, even offline, and are all aimed at improving communication, collaboration and overall project efficiency.
Interoperability
Interoperability is at the heart of ensuring connected teams and connected workflows and has been a constant theme at Trimble. For example, many of its MEP tools have been developed to work within the Autodesk Revit platform. While Trimble Connect essentially acts as the glue that holds together its entire portfolio of solutions and allows the sharing of data across projects and between products.
Taking this one step further is the connectivity between software and hardware, including Trimble’s Total Stations and scanning equipment. Here, interoperability enables users to take data from the factory or field and into the drawing office (and vice versa) with ease. While machine control and automation can utilise the informationrich data contained within the 3D model and use Trimble Connect to share that data for setting out on-site.
Productivity gains
It’s clear that digital workflows and software-hardware interoperability can deliver real productivity gains for the offsite sector. With enhanced speed, automation and efficiency, teams can spend less time on detailing and less time on site, with improved accuracy, coordination and communication. For us at Trimble, it’s all about aiding manufacturers and contractors in delivering on what the offsite methodology promises – enhanced speed, safety, quality and sustainability.
Images: 01-02. Workflow optimisation is at the centre of successful offsite manufacture
LIGHT STEEL FRAME
LIVING WITH STEEL FRAME
As we enter a new era of building safety, the Light Steel Frame Association (LSFA) are helping developers gain a better understanding of the speed and safety benefits light steel frame construction can bring to all housing providers. 1
Following the reset of housebuilding goals, councils and local authorities in England have new mandatory targets to pave the way to deliver 1.5 million more homes over the next five years. Under the previous administration, targets were relegated to ambitions in the final years of government. Now they are being reinstated as mandatory and to make up the shortfall in the first year, the objective is to build 370,000 homes year on year over the lifetime of the parliament.
Behind bold ambitions, robust plans are required – from planning and finance reforms to grants and a commitment to improve living standards. But critically to ‘get Britain building again’ councils and local authorities must ensure they have a
complete and compliant supply chain in place to deliver sustainable homes at scale that will stand the test of time.
Cost-effective option
Rapid and robust, light steel framing technology is a cost-effective option for residential construction projects. As a material it is safe and sustainable, being lightweight, airtight and durable. Low carbon – and in future NO carbon steel – will make steel the lowest carbon structural building product available. Delivering the requirements of the Building Safety Act and the Future Homes Standard, light steel has a massive part to play in delivering the challenging new housing targets, with frames assembled quickly and easily on-site and reducing labour costs significantly.
Building a safer future
An economic and versatile form of construction for residential buildings, robust steel frames are especially well-suited for meeting the rigorous requirements of the Buildings Safety Act.
Fire safety during construction and when the building is in use can be a significant issue with some forms of construction. According to our technical partner, the Steel Construction Institute (SCI) – the key benefits of light steel construction in relation to fire safety are:
• Steel is non-combustible and does not add to the fire load of the building
• The fire risk is much lower for light steel framing than timber construction
• No welding is required vastly reducing the risk of fire during construction
• With suitable board protection, fire resistance periods of up to 120 minutes are achievable
• Steel connections are robust in fire scenarios.
Stay safe – specify light steel
Trusted and widely specified by the UK construction industry – the digitally savvy light steel sector is an advanced industrialised construction method and highly mechanised – increasing quality, accuracy and production output. Manufacturing LSFA members have developed infill, panelised and modular solutions that deliver high quality buildings on fast-track construction programmes. Meeting the most stringent of building regulations and building safety standards, there is a well-established design, engineering, manufacturing and installation infrastructure.
LIGHT STEEL FRAME
Currently, it is estimated that only a third of all construction products in manufacture are covered by the Building Safety Regulator, leaving around 20,000 to 30,000 unregulated products.
Fire performance must be at the top of the list of priorities when specifying materials. The SCI and industry collaborators from the Light Steel Forum have carried out fire tests on loadbearing light steel framed walls. A stringent series of two-sided fire tests were conducted, SCI analysed the results which are detailed in the new SCI publication P442. Many LSFA members are BOPAS Accredited which certifies a design life of 3
LIGHT STEEL FRAME ASSOCIATION
60 years. But according to SCI, design life predictions for light steel in a ‘warm frame’ environment is in excess of 250 years, vastly reducing remedial and maintenance work for the lifetime of the homes.
The LSFA works to drive engagement, champion change, and spread the word about the cost, productivity, performance and sustainability benefits of contemporary light steel systems. Bringing together a wealth of experience and technical know-how, the LSFA membership represents manufacturers, installers, industry supply chains, architects, engineers, consultants and clients operating in the light steel sector.
For more information and to download ‘Light Steel Frame Meeting Your Housing Targets’ visit: www.lsf-association.co.uk/library
Images:
Sandgate Pavilions. Courtesy Ayrshire Metals
Abbey Wall Development. Courtesy Intrastack
THE CIRCULAR BENEFITS OF MODULAR CONSTRUCTION
As businesses move away from the ‘take, make, dispose’ linear model and seek to operate in a more circular fashion, Richard Hipkiss, Development Director for the Modular and Portable Building Association (MPBA), explains how modular construction plays a pivotal role in this transformation.
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The concept of circular construction is based on creating build systems that maximise the use of resources by reducing waste, reusing materials and recycling products. In the construction industry, which is known for its resource-heavy processes and significant waste, applying circular principles can have profound benefits. Traditional construction methods often involve the extraction of raw materials, large amounts of waste and the eventual demolition and disposal of buildings.
By contrast modular construction presents an opportunity to rethink the entire lifecycle of a building. The design of structures that can be easily dismantled, repurposed or refurbished – reduces waste and adds longevity to the sustainability equation.
Rethinking the building lifecycle
Volumetric modular construction is inherently more resource-efficient than traditional construction. As the
modules are built offsite in a controlled factory setting, there is much less waste generated compared to on-site construction. Digital technology means the use of materials is optimised and precision in the manufacturing process, reduces waste. Factorybased construction allows for the specification and validation of better materials so there is less likelihood of defects that generate rework and waste.
One of the key principles of circular construction is designing build systems that are adaptable. Factory manufactured buildings can be easily reworked, expanded, or modified to suit changing needs. In schools, for example, the design can accommodate future growth or changes in educational methods. Similarly, in hospitals, modular units can be reconfigured to meet evolving healthcare needs, such as adding more patient rooms, creating specialist units, or reconfiguring
spaces to accommodate new medical technologies.
End-of-life considerations
A critical aspect of circular construction is considering the end-of-life at the conception stage. Traditional buildings, once they reach the end of their useful life are often demolished. However, volumetric modular buildings can be disassembled and their individual components reused, refurbished, or recycled. For schools and hospitals, this means that modular buildings could potentially last for decades, with the ability to be updated or reconfigured as needs evolve. Additionally, materials used are often specified with recyclability in mind, further reducing environmental impact.
Portable buildings – the ultimate in circularity
One area where circular construction is making a notable impact is in the portable buildings sector. When leased, volumetric portable buildings
CIRCULAR ECONOMY
bring a host of benefits aligned with circular principles, resource efficiency, waste reduction and longer product lifecycles. Key to a circular approach is maximising resource efficiency –keeping materials in use for as long as possible and reducing waste.
Unlike traditional buildings that are often constructed with materials that can be difficult to repurpose or recycle, portable buildings are designed to be reused, reconfigured and relocated. Lease hire modular buildings are regularly maintained and reused by different clients over their lifespan. This leads to a significant reduction in the need for new resources, as buildings are continually refurbished and returned to circulation rather than being discarded after a single use.
Waste reduction and minimisation Another significant advantage of portable building lease hire is the reduction in construction and demolition waste. When the lease of a modular building ends, it can be transported back to the factory of origin, refurbished and reassembled – ensuring that much of the structure and fit-out materials remain in use. This approach is a far cry from the traditional model, where buildings are demolished at the end of their lifecycle and much of the waste ends up in landfill. By embracing portable buildings on lease hire contracts businesses contribute to the circular economy by ensuring that materials are recycled and reused rather than discarded.
Modular buildings are also renowned for longevity and adaptability. These structures are designed to be durable and can last for decades. Unlike traditional buildings that are fixed in place, portable buildings are highly adaptable. They can be reconfigured to meet the changing needs of different businesses or relocated to different sites based on demand. For example, a modular building used for temporary office space in one location may be leased out for use as classrooms or healthcare facilities in another area after the original lease expires. This adaptability allows businesses to optimise buildings and budgets, reducing the need for new construction projects and in turn, decreasing the environmental impact associated with creating new structures.
Moving towards a more circular future I firmly believe that volumetric modular and portable buildings align with the principles of circular construction. This most advanced of offsite methods promotes resource efficiency, waste reduction and longevity, whilst providing a flexible and cost-effective solution for businesses in need of temporary or adaptable spaces. As the demand for sustainable practices continues to grow, embracing modular buildings offers a fast and efficient way to reduce environmental impact and move towards a more circular, sustainable future in construction and building use.
MPBA
Founded in 1938, the MPBA plays a key role in connecting all sectors of the modular and portable building industry. Members gain a strategic advantage, with access to a network of resources and platforms that amplify and influence. As part of a dynamic community, the MPBA provides an environment where like-minded professionals collaborate, share ideas and forge meaningful connections that drive innovation and growth.
We understand the importance of continuous learning, which is why the MPBA founded its own dedicated Learning & Development Centre, to support personal and professional growth within the sector. Above all, we are driven by collaboration, energy and a forward-thinking attitude – continually pushing the boundaries of what is possible in offsite construction. We are the industry leaders, technical experts and champions of our sector.
For more information visit: www.mpba.biz
Images:
01. Richard Hipkiss, Development Director, MPBA
02. Dinas Powys Primary School.
Courtesy Wernick Portable Buildings
03. Volumetric modular and portable buildings align with the principles of circular construction. Courtesy Portakabin
SOCIAL HOUSING
COMMUNITY CREATION
The UK’s social housing crisis is at a critical juncture. With temporary accommodation costs spiralling and local authorities under immense financial strain, the need for bold and innovative solutions has never been more urgent.
One of these forward-thinking solutions is being provided by Boutique Modern, that has just launched ModernHome – the result of years of thoughtful design, strategic partnerships, and a deep understanding of the real-world barriers local authorities and housing association’s face.
ModernHome offers local authorities a way to house people in need quickly and affordably, without the capitalintensive requirements of traditional development. With lease models aligned to Local Housing Allowance rates, a BOPAS-certified 60-year build system, and a factory-first approach rooted in sustainability, ModernHome is designed to be scalable and offer immediate impact and long-term value for councils, investors and residents. Boutique Modern will also provide a planned and responsive maintenance service to all products including compliance checks, warranty renewals and component inspections.
Meeting an urgent national need
The launch comes after recent data from the Local Government Association (LGA) revealed the number of households in temporary accommodation has surged by 89% over the past decade. Importantly, the approach is grounded in a commitment to community, dignity, and regeneration.
“What inspired the development of ModernHome was simple,” says Managing Director of Boutique Modern, Dick Shone. “We saw councils spending eye-watering sums on emergency accommodation – hotels and B&Bs that aren’t suitable for longterm living – while people in real need were left in limbo. We knew modular construction had the potential to do more than just save money. It could deliver better homes, faster, and offer dignity and stability to those who need it most.”
Unlike some modular solutions that focus on premium apartments or private rental, ModernHome was designed from the outset to meet the needs of local authorities and housing associations. With its rapid delivery model, low operational costs and a unique lease arrangement aligned with Local Housing Allowance, it removes the usual barriers to getting homes built – especially levels of high upfront capital costs.
A real world response
The launch of ModernHome comes as the national housing shortage becomes increasingly urgent. In the 2022/23 financial year, councils spent more than £1.74billion on temporary housing, largely due to the shortage of social housing and rising private rental costs, according to the LGA. In Eastbourne, the council has been spending £4.5million on temporary accommodation, which equates to 49p in every £1 collected in council tax.
With Labour’s pledge to deliver 1.5 million homes during the next Parliament, modular and offsite construction must play a central role in speeding up delivery. “Labour’s ambition is welcome,” adds Dick. “But it will only be achieved if we embrace smarter, more agile methods of construction. Modular and offsite aren’t just quicker – they’re more sustainable, cost-efficient and flexible. ModernHome can be deployed in months, not years, and relocated as local needs change. That kind of adaptability is exactly what local authorities need right now.”
Each ModernHome scheme can be tailored to the specific demands of a local area – from studio flats to four-bedroom apartments, up to four storeys. Designed in partnership with Fuse Architects, the homes are built to enhance the local street scene and are intended to be pleasant to live next to, as well as to live in.
Dave Hughes, Design Director of Fuse Architects, says: “It is a privilege to work with Boutique Modern on this innovative and much needed housing product to address the shocking lack of temporary and affordable housing in this country. ModernHome provides a high quality, sustainable and viable, immediate solution, to this problem and we are proud to be involved.”
“The speed with which ModernHome can be delivered and installed must not be understated. Given the temporary housing costs paid by councils are astronomical, the quicker we can begin to reduce that burden the better. Furthermore, the temporary and relocatable nature of ModernHome enables transitional housing to be provided across a huge number of empty meanwhile use sites, as well as infill sites and excess land that is owned by councils and registered providers in a practical manner.”
Sustainability and social value
As the UK’s only B Corp-certified modular construction company, Boutique Modern brings a unique approach to building. Far from compromising its principles to deliver ModernHome, the company has leaned even further into its ‘purposedriven’ ethos.
SOCIAL HOUSING
“All our homes are built in our factory in Newhaven using a BOPAS-certified system with a 60-year design life and a focus on low energy use and easy maintenance,” explains Dick. “We’re serious about environmental standards, and we design every home with its end-of-life in mind –disassembly, reusability, recyclability – it’s all part of the plan.”
Boutique Modern has also joined the Prisoners Building Homes initiative run by the Government, Ministry of Justice and the Ministry of Housing, Communities and Local Government, which will see the contractor partner with Ford Open Prison to employ people serving sentences in the Newhaven factory and in office roles, unlocking up to 100% funding for local authorities to pay for planning permission and up to £10,000 per home towards infrastructure on sites using ModernHome. “We’re committed to doing things the right way,” adds Dick. “That means thinking about social value, environmental impact and long-term affordability –not just headline-grabbing delivery numbers.”
A new model for local housing delivery
One of ModernHome’s key strengths is its flexible financial model. Councils can lease the homes directly from Boutique Modern with monthly payments in line with their Local
Housing Allowance for up to 15 years – removing the need for upfront capital. For cash-strapped authorities, this model is already proving highly attractive, especially when paired with the speed of deployment.
With pilot schemes already in planning, and interest growing across London and the South East, Boutique Modern believes ModernHome could represent a turning point for local housing provision. “Too many housing schemes are delayed by bureaucracy, cost overruns or poor community outcomes,” says Dick. “With ModernHome, we’ve created something that’s quick, affordable, sustainable and – most importantly –a genuinely good place to live.”
As the demand for social housing continues to rise, and councils face mounting pressure to stretch ever-tighter budgets, solutions like ModernHome could prove vital in bridging the gap and as Dick Shone and Boutique Modern are proving, it’s not just about building homes – it’s about building better futures.
For more information visit: www.boutiquemodern.co.uk
Images: 01. Dick Shone, Managing Director, Boutique Modern 02-03. The ModernHome will offer local authorities and registered social housing providers a new option for speedily delivered quality accommodation
MMC IRELAND HITS THE MARK AGAIN
Bringing together key stakeholders, industry leaders, innovators and policymakers for a third landmark event – the MMC Ireland 2025 Conference was declared a resounding success.
Held on 11-12 March at the Johnstown Estate, Enfield – the twoday conference drew a diverse and sizable audience. From construction clients and housebuilders to offsite manufacturers and digital technology providers – all delegates and exhibitors were eager to engage in meaningful dialogue and knowledge exchange to accelerate the adoption of offsite and industrialised construction.
The MMC Ireland National Conference has established itself as a key event in the industry, bringing together professionals, policymakers, and innovators to advance the discussion on modern methods of construction (MMC). Chaired by Darren Richards from offsite experts, Cogent Consulting
– the positivity surrounding the event did not go unnoticed with a deluge of support on LinkedIn as well as the formal feedback following the event.
Attendees commended the conference for its quality of speakers and seamless organisation. One delegate remarked: “Overall I really enjoyed the conference and gained excellent insight from a significant number of stakeholders.” Others echoed this sentiment, adding: “The level of knowledge and debate at the conference was very impressive. It was a fantastic conference, very well organised with great speakers. One of the best events I have been to in years!”
Nicola McKay, Belfast Studio Director for HLM Architects said: “A key takeaway from the conference was how Ireland is learning from the rest of the world, exploring lessons learnt from the UK, Europe, and the US to refine its approach. This knowledge exchange and collaboration is crucial for ensuring that MMC is implemented effectively.”
Anne Daw, Head of MMC Delivery at HLM Architects added to this saying: “The investment in research and policy development of the Irish government is commendable. They have picked up the key issues quickly and put actions in place to advance the development of MMC at all levels.
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MMC IRELAND 2025
“That energy and clarity has encouraged the industry to respond with their own investment, challenging traditional approaches and bringing innovation to the table, particularly in the areas of digital innovation and sustainability. MMC Ireland 2025 provided an excellent forum that brought together all the key stakeholders and facilitated meaningful discussions across a broad range of topics. The best part, however, was meeting industry peers face-to-face, forming personal connections that will drive forward future innovations.”
A word from the top MMC Ireland’s Chief Executive, Paul Tierney, reflected on the success of the event, the key themes that resonated with delegates and the factors driving Ireland’s leadership in MMC. Central to success in Ireland has been the strong collaboration between government and industry, the growing focus on carbon optimisation and the international reach of Irish companies in the MMC sector.
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“It was a fantastic conference, very well organised with great speakers. One of the best events I have been to in years!” Another delegate added: “The event team were the most willing hosts, and I could not fault their enthusiasm, energy and organisation. The whole event was professional and fun – a combination many fail to achieve.”
“The event went very well. We’ve had a lot of feedback from the delegates, sponsors, exhibitors, speakers, and panellists, and it has all been very positive. Many delegates have said they’re looking forward to next year, and they’ve really praised the quality of the speakers and their content. So overall it went very well, and I’m very happy.”
Key themes and topics that resonated with people throughout the conference included digital and industrialised construction, with AI all very prominent. “We saw a really
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strong demonstration of live digital twin technology in operation which is at the final stages of going live." added Paul. "That was presented by HLM Architects and Cairn Homes, and I have to say, it was really impressive. In my opinion, it’s a great template that could be rolled out across the UK, particularly within local authorities.
“Another major theme was the growing momentum behind carbon and sustainable construction, led by Sisk. They gave an excellent presentation on how they evaluate projects from a carbon optimisation perspective. That was presented by Sarah-Jane Pisciotti and Juan Morillas, and it was very insightful. It really highlighted the increasing importance of carbon footprints in project evaluations, not just for Sisk, but also for their clients.
“A final standout aspect was the number of presentations from government representatives. The Department of Housing and Construct Innovate discussed the growing support for MMC from the Irish government. They also outlined their plans to standardise MMC
MMC IRELAND 2025
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DAY ONE HIGHLIGHTS –Government, Competency & Digital Innovation
The first day opened with pre-event networking, followed by presentations from Éadaoin Ní Fhearghail of the Department of Housing, Gavin Lawlor from the Irish Planning Institute, and Dr Daniel McCrum from University College Dublin, who highlighted current initiatives, planning integration and standardisation strategies.
Mid-morning sessions focused on the ‘Competency and Capability to Deliver’, featuring expert insights from architectural and project management professionals, including Gareth Maguire, Director of Reddy Architecture and Darragh Ryan, Head of Commercial - Ireland at Remagin.
This was followed by a deep dive into the subject of ‘Digital Technology as the Enabler’, showcasing innovations in AI, digital platforms, logistics and automation. Speakers included Helena Lidelow, Chief Technology Officer at Volumetric Building Companies, a joint presentation from Ronan Lonergan MRIAI, Design Lead - Innovation and PreConstruction at Cairn Homes and Anne Daw, Head of MMC Delivery at HLM Architects, Matthew Osment, Director/Consultant at Shift Construction, and Cesar Fragachan, CEO-Founder of Aalter AI.
The day concluded with a session on Sustainable Offsite Solutions, with Sarah-Jane Pisciotti, Innovation & Design Director and Juan Morillas, Head of Sustainable Design, both of SISK exploring regenerative design and carbon lifecycle challenges, along with Ann-Marie Fallon, Associate Director of Architype, before a networking drinks reception closed the evening.
DAY TWO HIGHLIGHTS –Platform Design, Certification & Skills Development
The second day opened with a focus on ‘Platform Design and Industrialised Construction’, led by Darren Richards of Cogent Consulting. Speakers Ben Carlisle, Global Practice Leader - Industrialised Design and Construction at Mott MacDonald, Bryn Griffiths, Director of Turner & Townsend and Martin Searson, Head of MMC Certification at the NSAI addressed collaborative delivery models, certification updates and the tangible benefits of standardisation.
manufacturing details, which will be open sourced to the market. This is a huge opportunity for both new entrants and existing companies that may not have the resources to go through an Agrément certification process or a BOPAS accreditation process. With these standardised details, companies that follow them will have built-in accreditation. That’s groundbreaking to me, and it’s a fully government-funded initiative, which is really exciting.”
With MMC doing particularly well and its profile rising, has Ireland captured something special and what is the secret to its success?
“I think it’s led by a combination of factors,” said Paul. I’ve spent 20 years working in the UK, and I’ve recently moved back to Ireland, where I now spend at least half my time. Through my role with MMC Ireland, I’ve been working closely with the Irish government, particularly on residential projects but also in other sectors."
“I had never worked so closely with the Irish government before and I have to say, I’ve been really impressed. Not just by the politicians, but especially by the principals within the civil service in those departments. If I compare Ireland to the UK, I think Ireland has the advantage of being more agile. We are a smaller country, and that allows for greater flexibility. The system is built on trust and relationships, and the government genuinely wants industry involvement.
Late morning and early afternoon sessions shifted attention to ‘People Development and Industry Skills’, with a new chair, Dick Clerkin of Clerkin Consulting. Topics ranged from apprenticeship development and skill-building schemes to cultural change on construction sites. The session featured Alan Hore, Founder of CitA, Joseph Little, Head of Construction at TU Dublin, and Bernard Brogan, Co-Founder of PepTalk.
A final panel debate addressed the challenge of attracting and retaining talent in the sector, before MMC Ireland CEO Paul Tierney delivered a succinct event summary. The conference officially concluded with a networking lunch.
“They’re not afraid to admit they don’t have all the answers, and they actively seek input from industry. It’s a true collaboration, and through organisations like MMC Ireland, that trust has been built up. While it’s a small island, its reach is global. Exporting is in the DNA of many Irish companies. A lot of organisations, including those I’ve worked with in the past, have been exporting to the UK for the last 20 years, so while the Irish market itself is relatively small, the market for Irish businesses is global.
“Irish companies like Errigal, Clancy, Jones Engineering, and Mercury are market leaders in data centres
MMC IRELAND 2025
worldwide. The buildings they manufacture, and construct are all built using MMC. These companies think globally, and the government is leading the way in helping the industry become more sustainable.
Government seal of approval
Shortly before Paul Tierney’s closing comments, the audience heard from Marian Harkin, Ireland’s Minister of State for Further and Higher Education, Research, Innovation and Science.
Quoting her relative lack of knowledge of the offsite sector, Marian credited the speakers over the two days for breaking down complex subjects into something easier to understand and promised further government backing.
“I’m just two weeks into the job, and while I’m immersing myself in plans, programmes, and policy documents, I find – personally – that one of the best ways for me to learn is by attending
conferences like this,” said Marian. “Where I can hear directly from the experts and from those who truly understand this sector.
“From everything I’ve seen and heard, this event has gone from strength to strength over the years. I look forward to attending in my capacity as Minister in the coming years, where I hope to ask increasingly intelligent questions, and perhaps answer a few of them too.
Although this is my first time attending this conference, I understand that it plays a central role in bringing together representatives from industry, further and higher education, and government to collaborate in pursuit of our shared goal, to advance MMC in Ireland."
Closing the successful two-day event
Paul Tierney said: “This is the most successful National Conference
MMC Ireland is the leading voice of the expanding offsite sector in Ireland. Dedicated to promoting and advancing the interests of members and the sector as a whole, MMC Ireland’s mission is to provide a unified voice, advocacy, and support to help sector pioneers grow and succeed. Once again in 2026 MMC Ireland will partner with event organisers Radar Media to build on this success.
Save the date: 04-05 March 2026, The Johnstown Estate, Enfield. For more information or to register your interest in the 2026 event contact Ellie Guest on: ellie.guest@radar-media.co.uk
to date in terms of engagement, speaker content and industry support. Momentum for this annual event grows year on year and we are able to use it as a catalyst for collaboration throughout the MMC supply chain and right up to senior levels in government. The event is a testament to the MMC Ireland Steering Group and the vision and ambition that we have to lead construction sector innovation. Roll on 2026 when we will be able to demonstrate further progress in the uptake of MMC and offsite technology application.”
You can find out more about MMC Ireland at: www.mmcireland.ie
Come and meet the MMC Ireland team and our members at www.offsite-expo.co.uk
Images: 01. Paul Tierney, Chief Executive, MMC Ireland 02. Marian Harkin, Minister of State for Further and Higher Education, Research, Innovation and Science 03-07. The two days saw top level discussion and knowledge sharing alongside networking and an exhibition
LIVING IN THE MILITARY
Defence needs supporting infrastructure to match the increase in spending and as Ian Astley, Regional Director for Premier Modular points out, modular construction can help.
HM Treasury has announced that the defence industry is not one of the National Wealth Fund’s priority sectors, leaving the UK to fund an increase in defence spending through aid budget cuts. With the government still seeking to accelerate its rearmament efforts and increase military spending, defence sector projects need supporting infrastructure to enhance delivery without financial strain. To maximise efficiency when pursuing ambitious targets – such as delivering new accommodation or refurbishing existing homes for veterans – the sector needs appropriate supporting infrastructure to ensure goals are met sustainably.
Staff accommodation
The biggest area in need of support is accommodation for staff, and most of the main defence spend has been set aside for this purpose. In October last year, the government announced grants totalling almost £3.7million for veterans’ capital housing. A huge amount of MoD accommodation is in a poor state due to years of
neglect and so far, the funding has replaced roofing, boilers, windows, provided insulation and accessibility modifications as well as other energy saving measures.
However, whilst the upgrades to veterans’ housing are positive, there is still work to be done on improving the MoD’s overall accommodation output, for example delivering new single living spaces. Modular construction will play a significant role in achieving this. Homes built using offsite construction can be constructed far quicker than traditional building methods, in as little as six months. They can be a mixture of layouts based on the Defence Infrastructure Organisation’s (DIO) common design, which reduces design periods and speeds up the construction process as the designs are already complete.
Although there’s a clear government objective to improve living accommodation for troops through a massive increase in spending, investment in the defence sector is not just limited to the troop arena.
There’s a sizeable ancillary supply chain in need of support, such as companies that are manufacturing and providing aircraft, submarines and other vehicles for defence purposes. As these companies naturally expand their operations due to increased defence spending and outputs, their projects will often need supporting infrastructure to rehouse growing design and commercial teams. This can take the form of temporary offices, welfare facilities for staff, offices for management and changing facilities. Offsite construction offers an ideal solution here, as bespoke, high-quality and cost-effective solutions can be tailor made and delivered at speed to the sites that need urgent support to keep up with demand.
There’s demand for both temporary and permanent solutions to support increased investment but looking ahead, it’s likely that there will be more need for permanent solutions in the defence sector. As contract periods can be extremely long, supporting infrastructure is needed long term. For example, in the aircraft industry,
DEFENCE
when a new product is conceived, the process for its design and development can take anywhere from five to ten years. Following this, the production of the new aircraft can take up to another ten years, by which point supporting infrastructure solutions are very much a permanent fixture on-site, whether a long-term rental or permanent building. This highlights the importance of using high quality, sustainable buildings to support defence projects.
Advanced manufacturing
Following the Spring Forecast announcement of an increased defence budget, part of the plan included a boost in advanced manufacturing production in certain regions. As development teams introduce artificial intelligence to advanced manufacturing, it’s expected that new jobs will be created, increasing demand for staff. Due to the highly confidential nature of a lot of
these projects, currently little is known about how much infrastructure will be required. However, modular buildings’ flexibility and scalability means they can adapt as demands change and grow and can be procured at very short notice.
Looking ahead, there are some changes that could be made in order to help the defence sector achieve its ambitions. Often, defence contracts are extremely lengthy, typically taking three to five years from inception to completion. Reducing the administrative processes, particularly within the defence procurement and approvals system, could bring significant benefits and streamline processes. Faster approvals would enable veteran accommodation projects to be delivered more quickly, providing urgently needed homes and upgrades for those who need them most. A faster, more streamlined approvals process would also bring
Images: 01. Ian Astley, Regional Director, Premier Modular 02-05. Modular construction can provide accommodation very quickly and with top quality 3 4 5
financial benefits. Material costs have risen with inflation, meaning delayed projects incur higher costs than originally accounted for, so speeding up the process would minimise this impact on quotes and maximise budgets.
The defence sector is already reaping the benefits of additional funding from the government, especially around veteran accommodation, but with spending set to increase, offsite construction could hold the key to ensuring the successful delivery projects, boosting the sector in the UK.
For more information visit: www.premiermodular.co.uk
TIME TO UPGRADE
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SCORING GREEN GOALS
Offsite construction’s environmental credentials and sustainability benefits are not spoken about enough. These issues are often lost amongst the well-understood concepts of factory precision, repeatability, risk reduction and quicker routes to quality.
But as net zero targets have focused minds on recycling, waste reduction, circularity and climate care, it’s worth looking at how offsite manufacture and its drivers stack up against the UN’s Sustainability Development Goals – those now widely accepted set of 17 interconnected goals outlined by the United Nations in 2015 to address global challenges surrounding sustainability, efficiency, and resilience in the built environment to reach a more sustainable future by 2030.
How Do Offsite Principles Align with the UN’s Sustainable Development Goals?
SDG 9: Industry, Innovation and Infrastructure
Offsite construction boosts innovation around industrialised construction by integrating advanced manufacturing techniques, robotics, automation and digital design to improve efficiency. It improves built environment quality by ensuring precision, factory-controlled conditions result in innovative architecture and structural engineering designs. Construction time can be cut reducing project costs and the environmental impact of waste to landfill.
SDG 11: Sustainable Cities and Communities
As often stated, offsite construction holds many answers to the UK’s housing crisis and can provide affordable, and scalable housing solutions to tackle urban housing shortages, especially in the social housing sector. Minimising on-site construction activities reduces local disruption, construction transport, noise and pollution associated with many traditional sites. Design for deconstruction and demountable components provide adaptable buildings, essential for futureproofing, lifestyle changes, repurposing of structures and more mixed-use, vibrant communities.
Image: Courtesy Donaldson Offsite
OFFSITE & SDGS
SDG 12: Responsible Consumption and Production
Offsite construction significantly reduces material waste compared to traditional construction by using automation, lean manufacturing and digital workflows within controlled factory conditions. Many offsite construction methods already incorporate naturally renewable and low carbon materials such as timber, many recycled materials and generally support circular economy principles, where components can be repurposed. Again, offsite manufacture reduces construction-related landfill waste – a major environmental issue.
SDG 13: Climate Action
Offsite methods can lower carbon emissions by reducing transportation needs, minimising onsite construction energy use, and integrating energy-efficient materials. Offsite manufactured buildings and components are designed with energy efficiency in mind including better insulation, passive heating/cooling and can integrate net-zero microgeneration systems including solar PV, battery storage and smart energy controls.
SDG 8: Decent Work and Economic Growth
Less site-work and working at height improves health and safety and reduces constructionrelated injuries and accidents. Offsite construction generally creates safer and more controlled working environments. It also increases diversity, gender equality, develops transferable skills with more job opportunities in technology, robotics, digital design and logistics and sustainability. Productivity is improved by reducing on-site inefficiencies and delays.
SDG 6: Clean Water and Sanitation
Prefabricated MEP systems reduce water consumption and waste by using efficient plumbing systems and recycling water. Many offsite-designed buildings integrate rainwater harvesting and water-efficient appliances. Bathroom pods are high-quality standardised units that provide massive benefits in water efficiency and quality design.
SDG 7: Affordable and Clean Energy
Many offsite manufactured buildings are designed to integrate solar panels and energy-efficient heating systems, with zero-energy and passive house designs. Factory facilities are increasingly incorporating solar panels to reduce costs and energy demand and using electric vehicles. Overall operational energy associated with construction is reduced by shifting production to controlled factory environments and minimising site-work.
SDG 3: Good Health and Well-Being
Controlled factory environments minimise exposure to site-based hazards and improves construction health and safety. High-quality indoor air standards can be achieved through lowVOC materials and advanced ventilation systems. Timber-based buildings in particular deliver many biophilic and wellbeing benefits. Factory employment and use of local supply chains provides high social value and attracts a more diverse, flexible and happier workforce.
With far reaching and noble aims, the SDGs cover all sorts of issues effecting all walks of life on a global basis. They are essentially a progressive framework for businesses and individuals to increase efforts to tackle major global challenges such as climate change, material shortages, urbanisation and better living conditions. The SDGs emphasise that ‘no one should be left behind in the pursuit of sustainable development’. Offsite manufacture in all its guises and materials can be seen as part of trying to do this and take the built environment and everything connected to it towards a better place for future generations.
If you haven’t already read, understood and got to grips with the UN’s 17 Sustainable Development Goals visit: https://sdgs.un.org/goals
09:15 Registration, Exhibition Viewing and Networking
10:10 Keynote: Edward Jezeph, Homes England Investment and Affordable Housing Market Delivery
10:30 Katie Rudin, Akerlof & Anne Daw, HLM Architects Platform Design/Pattern Book Developments for Low-rise Housing
10:50 Christian Nielson, Swedish Wood Supply-chain Challenges Associated with Market Expansion
11:10 Adam Gravely, Future Homes Hub Collaboration for the New Homes Sector to Help Meet the Climate and Environmental Challenges Ahead
11:30 Oliver Novakovic, Barratt Redrow Vertical Integration of Timber Frame Technology and Self-supply
11:50 Q&A
12:00 Refreshment Break, Exhibition Viewing and Networking
SESSION 2: Sustainability & Low Carbon Challenges
12:40 Paul Brannen, Confederation of Timber Industries (CTI) Timber! - How Wood Can Save the World from Climate Breakdown
13:00 Anna Lisa McSweeney, Built By Nature Sustainability of Timber Construction
13:20 Ann-Marie Fallon, Architype The Challenges of Reaching Passivhaus Standards
13:40 Q&A
01.10.2025 NCC, BIRMINGHAM
13:50 Headline Exhibitor Audience Address
14:00 Lunch, Exhibition Viewing and Networking
SESSION 3: Industrialised Construction –Expanding Timber Systems Manufacturing Capacity
14:40 Stewart Dalgarno, Structural Timber Association Timber Growth Project Update
15:00 Panel Debate: Facilitated by Darren RichardsCogent Consulting Alex Goodfellow, Donaldson Offsite Peter Blunt, Innovaré Offsite
Oliver Novakovic, Barratt Redrow Ola Skoglund, Randek Robotics
15:25 Jack Brayshaw, Vistry Group
Top 5 Housebuilder Investment in Volume Timber Manufacture - Case Study on Largest Scheme
SESSION 4: Timber Application Case Studies
15:45 Victoria Hale, dRMM Adaptation of Prototype Housing Schemes. How to Re-think Traditional Design
16:05 Charlotte Hale, SO Modular
Volume Delivery of Affordable Housing Using Timber Solutions - Panellised and Volumetric Modular
16:25 Alex Brock, B&K Structures
Design & Delivery of Hybrid Structures
16:45 Kelly Harrison, Whitby Wood Optoppen Technology - Rooftop Extensions
17:05 Q&A
17:15 Chairmans Event Summary
17:20 Conference End
18:00 ST AWARDS DRINKS RECEPTION
STRUCTURAL TIMBER
MODULAR APPROACH BRINGS NURSERY TO LIFE
Utilising the benefits of timber and modular construction, TG Escapes has delivered a highly sustainable and energy efficient nursery building for the village of Paulton in Somerset.
The building, which will provide a valuable resource for the local community, was constructed in just 12 weeks and designed to be net zero in operation. The Paulton Nursery is a 60-place early years facility for under-fives and is part of a wider and ongoing redevelopment of former commercial land, which has brought new homes to the area. TG Escapes, the award-winning supplier of ecofriendly educational buildings was involved from the early stages of the project following a recommendation to the developer from a previous TG Escapes customer.
TG Escapes’ experienced in-house team undertook the design and specification of the building in collaboration with the developer and the architects working on the wider redevelopment. The nursery was designed to have the smallest possible environmental footprint. In addition to the extensive use of timber, the building was designed to maximise energy efficiency and features an air-source heat pump to provide heating and a rooftop solar PV array to generate electricity.
The single storey building features modular pre-insulated timber frame panels for the exterior and interior walls with structural elements manufactured from glulam and timber Posi-joists for the roof. These elements were manufactured in the TG Escapes factory in Coventry and transported
to site on a ‘just in time’ basis and assembled. The outside of the building is completely clad in Thermowood – a heat-treated timber – which provides a natural appearance that helps the building blend with the green public space that forms the other half of the redeveloped site. Thermowood also delivers excellent durability and weather resistance.
Dan McAleer, Sales Director at TG Escapes said: “We have long championed the use of sustainably sourced timber in construction. For a learning environment in particular, timber is an ideal choice as a natural, warm and welcoming material. Beyond this, with sustainability now a priority, many clients are keen to look at net zero more holistically by considering both energy in use and embodied carbon. It is increasingly clear that net zero embodied carbon is only possible by using timber, due to its carbon sequestration properties.”
Using offsite construction in the form of the modular manufactured elements, meant that the time required on-site was minimised and delays avoided. Despite the construction taking place during three months of persistent rainfall, progress was not impacted by the weather. With groundworks completed, the superstructure was weathertight in under three weeks with the building finished in just 12 weeks – exactly in line with the program set out during planning.
The controlled factory environment allowed increased accuracy and improved quality control, helping to achieve the high levels of energy efficiency. The swift on-site construction and reduced material
deliveries also helped to minimise disruption to the wider scheme where a second phase of the housing development was being completed as well as soft and hard landscaping works in the surrounding areas.
TG Escapes is a member of the Structural Timber Association (STA) and holds STA Assure Gold status, showing the business demonstrates the highest levels of quality, compliance and best practice as a provider of structural timber buildings. STA Assure, the association’s quality assurance scheme, is recognised by a range of industry-leading structural warranty and building control bodies as well as other stakeholders such as insurers. Commenting on the value of STA membership, Clive Hicks, Project Manager at TG Escapes said: “The combination of timber construction and MMC has numerous advantages, but for many clients it is still a departure from their tried and trusted approach to projects. Being a member of the STA gives us genuine credibility as a business and means clients can have confidence that everything we do, from design to manufacturing to construction on site, will be fully compliant and completed to the highest standards.”
You can watch the case study video about this project here: https://www. youtube.com/watch?v=x8iaFVy61Dc
For more information visit: www.tgescapes.co.uk www.structuraltimber.co.uk
Images: 01-02. Timber and modular construction combined to create a highly energy efficient nursery that was delivered in just 12 weeks
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The perfect partner offsite sector
DRIVING TRANSFORMATIONAL CHANGE
The offsite sector’s flagship event returns later this year with fresh features and a renewed impetus on demonstrating the ways that offsite manufacture can transform our built environment.
The future of construction is intelligent, industrialised and sustainable. It involves new construction methodologies integrated with advanced manufacturing techniques and digital technologies to increase quality, safety, efficiency and productivity.
The challenges involve re-skilling the workforce, addressing building regulations and financial constraints as well as keeping pace with change to ensure companies are not left behind. With a mission to empower construction professionals, OFFSITE EXPO returns to the Coventry Building Society Arena and will take place from 16-17 September 2025
Over two days, invaluable knowledge can be gained that will revitalise career paths and support the development of new skills and specialisms. The focal point of Offsite Construction Week –taking place from 15-19 September – OFFSITE EXPO is a dynamic opensource event offering unparalleled opportunities to look at new horizons to address the issues that have plagued the construction industry for decades.
With an emphasis on construction industrialisation, kit of parts approaches and platform design, OFFSITE EXPO features the most comprehensive display of cuttingedge construction solutions, from 2D panelised and 3D volumetric modular solutions to ground-breaking pod technologies. But it is offsite pioneers and people who are at the heart of this event. Acting as catalysts for change, these industry innovators are influential in shaping the future of construction
and are front and centre in curating OFFSITE EXPO's highly regarded conference programme and dedicated exhibition.
Within the past year the construction sector has seen the spotlight land on procuring for quality, safety, value, sustainability and a move toward enhancing productivity via automation and digitisation. The evolution of industrialisation construction processes, supply chain integration and changes to building regulations and standards have influenced the change. This new emphasis will be covered throughout the two days across the conference programme and exhibition space.
CPD Certified Masterclass Seminars The MASTERCLASS SEMINAR programme makes freely accessible the latest thinking on the implementation of offsite methods from industry trailblazers and though-
leaders. With an emphasis on boosting productivity – the fusion between construction industrialisation and digital technologies will be under the microscope.
The intelligence gained will also be a game-changer for construction professionals looking to advance career opportunities. Helping fulfil CPD commitments, the free to access seminars present not only inspirational thinking and practical advice but will also take a deep dive into funding streams and housing policy, as well as examining the opportunities that are emerging in the education and healthcare sectors. Knowledge sharing and knowledge exchange is the primary objective of the seminar programme, with the potential to identify valuable collaboration opportunities.
This serves as a platform for collaboration and knowledge exchange within the offsite construction arena. BOS is dedicated to shaping the future of construction through collaboration, innovation and transformation and will invite OFFSITE EXPO delegates to join them and their members in this ‘free to access’ range of presentations that will explore ways to deliver a sustainable, efficient and resilient future for the built environment.
construction be leveraged to meet the growing demand for housing that is both cost-effective and sustainable?
• Skills and Competencies: a critical discussion on the future workforce. With the rapid evolution of technology and construction methods, how do we ensure that the next generation of workers has the skills and competencies needed to thrive in a fast-changing industry?
Running parallel with OFFSITE EXPO, this two-day series of informed presenters and discussion panels will share insights from the UK and further afield. After the outstanding success of the inaugural OFFSITE SUMMIT last year, this year’s event will once again be co-hosted by BUILDOFFSITE (BOS).
Roundtable Debates
Running across the two days of OFFSITE EXPO, the Offsite Alliance will host a series of dynamic and thought-provoking roundtable debates. These exclusive sessions will offer delegates the opportunity to engage directly with industry experts, gain insights and interact with highlevel discussions on some of the most critical topics shaping the future of construction. The roundtable debates will cover a range of emotive topics, including:
• Social and Affordable Housing: delving into the challenges and innovative solutions driving the development of affordable housing at scale. How can offsite
• Supply Chain Within the Factory: unpacking the complexities of modern supply chains within offsite manufacturing. How can we streamline processes, tackle disruptions, and build more resilient and efficient supply chains in the factory setting?
Do not miss your chance to be part of these insightful debates and contribute to shaping the future of offsite construction.
New for 2025 – Digital Demos
A first for OFFSITE EXPO. The 2025 event will see the launch of the Digital Demos arena. Digital construction is a powerful way to increase productivity by eliminating inefficiencies, providing more accurate insights and improving communication across various stakeholders — from architects to engineers to contractors.
With an emphasis on construction industrialisation, kit of parts approaches and platform design, OFFSITE EXPO features the most comprehensive display of cutting-edge construction solutions.
Join us for a series of live demonstrations showcasing the end-to-end digital workflow of a building project. Leading experts from pioneering digital companies will take delegates through each key stage –from planning, site analysis, design to fabrication and facilities management – demonstrating how different digital tools integrate seamlessly at every step.
These sessions will highlight the innovation and interoperability between digital solutions, showcasing how each platform contributes to improving efficiency, collaboration, and sustainability in the project lifecycle. Do not miss out on this unique opportunity to ‘digital transformation in action’ and learn how these tools work together to deliver smarter, faster and more sustainable building projects.
Don’t Miss Out – Secure Your Place
As the first and leading event of its kind, OFFSITE EXPO is acknowledged for highlighting key industry issues and helping drive transformational change within the offsite sector. Connecting the offsite supply-chain with architects, engineers, consultants, contractors, project managers as well as developers and clients. The event also informs those involved in education and university research institutions, tech innovators invested in the future of construction, together with government policy makers and regulators who want to be futureready.
Spending two days at OFFSITE EXPO offers access to expert speakers, exclusive insights, product launches and workshops showcasing real-world applications of offsite technology. Learn about emerging trends, recent research, best practice procedures and offsite innovation directly from industry leaders, while importantly connecting with peers and potential business collaborators.
OFFSITE EXPO will take place on 16-17 September 2025 at the Coventry Building Society Arena.
Entry to the exhibition, CPD Accredited MASTERCLASS SEMINARS and the OFFSITE SUMMIT are FREE OF CHARGE. To book tickets go to: www.offsite-expo.co.uk
HOW TO OPTIMISE PIPEWORK FOR OFFSITE
Ben Bellward, Regional Sales Manager at GF Building Flow Solutions, explains how the right product and supplier choices can help maximise the quality and efficiency benefits of an offsite approach.
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For heating and plumbing systems, it is important to achieve the correct design and specification that aligns with the offsite methodology. There are several factors that need to be considered when selecting pipework and manifold systems for offsite projects. This includes the ease and speed of installation as well as durability and minimising the risk of leaks. Multi-layer composite (MLC) pipe is an increasingly popular choice for offsite construction as it combines the advantages of metal and plastic pipes.
MLC pipe is constructed from an aluminium core with internal and external layers of polyethylene. This construction gives the pipework strength and durability as well as flexibility. This flexibility means the pipe is easily manipulated by hand or using handheld tools to create a bend rather than two sections being connected using an elbow joint. This not only speeds up installation, but it also reduces costs, eliminates the potential for leaks and helps maintain system pressure by minimising the number of connections.
However, not all MLC pipes deliver the same level of performance. A careful evaluation of different options available is essential to ensure the best possible specification. For example,
Uponor Uni Pipe PLUS achieves a 40% tighter bending radius compared to other multilayer pipes, which can reduce the number of required fittings by up to 15%, further boosting installation speed and efficiency. The fittings used should also be assessed, as this can make a significant difference to the performance of the system and the speed and reliability of the installation. Uponor S-Press PLUS fittings have a flow-optimised design that reduces pressure losses by up to 60% as well as a simple threestep installation and a reliable press indicator to quickly identify correctly pressed connections.
It is also important to consider the supplier itself, especially as not all manufacturers understand the requirements and specific challenges of building offsite. Leading system manufacturers will be able to go beyond product supply, to offer comprehensive support and guidance throughout the project.
It is valuable to find a manufacturer that can work collaboratively to provide input into the design at the earliest stage. At GF Building Flow Solutions, we have worked with many clients on the design for offsite modular builds to create a finalised design as early as possible in the project, allowing better planning of
the work. This early engagement also helps ensure the design is optimised, ultimately reducing complexity and costs as well as making it easier for the installation team.
A further way that leading suppliers can support the project is by providing on-site installer training to ensure best practices are followed. This is particularly valuable where the installation team are not familiar with the product or are not plumbing specialists. During installation, the supply partner should also be able to review progress and identify any deviations from the recommended techniques to ensure quality standards are maintained across all modules. Partnering with the right supplier can provide comprehensive support and high-quality products and will help ensure the success of the offsite construction process.
To find out more about Uponor products from GF Building Flow Solutions and how these can support offsite schemes visit: www.uponor.com
Images: 01. MLC pipe can be easily manipulated by hand or using handheld tools to create a bend rather than two sections being connected using an elbow joint 02-03. Offsite projects demand high quality with speed, so a specialist installer is required
precast
DEDICATED TO THE DEVELOPMENT AND APPLICATION OF PRECAST CONCRETE
Derisking Healthcare Construction Using Precast Concrete Techniques
DATA CENTRES
How does precast fit into the world of AI and machine learning?
FOUNDATION PACKAGE A comprehensive precast solution is helping transform Kettering housing
MOVING PRECAST PANELS A new loader has arrived to make material movements safer and easier
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LOOKING FOR MASS SOLUTIONS
Welcome to our special magazine section spotlighting some recent news, projects and issues within the precast concrete sector. Two key pieces inside highlight the strengths that precast concrete – allied to offsite delivery – can offer the healthcare sector and the burgeoning world of data centres. Firstly, Mark Shepherd, Director at MPA Precast and MPA Masonry, offers some ways that ‘repeatable construction’ is central to derisking healthcare projects within the remodelled New Hospitals Programme (NHP). The adoption of more offsite construction and component-led design is also the only way that the NHS can deliver the facilities the UK desperately needs quickly.
Secondly, precast concrete specialists FP McCann outline why the material is so appropriate for the data centre sector. Central to all our lives – without us really knowing it – new technologies driven by artificial intelligence and machine learning are booming. Because of these new demands a significant increase in capacity and construction of safe and secure facilities is required – precast concrete and thermal mass may have the answer.
Precast concrete is well understood for its structural strengths, solid reliable mass and its ability to suit a variety of applications and sectors and because of this is specified to provide stable solutions in all sorts of ways. Some examples of this you will find over the next few pages, including a comprehensive precast foundation package solution from Roger Bullivant and a new piece of kit from Combilift that is ideal for moving precast panels.
PRECAST CONCRETE
OVERLEAF…
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REPEATABLE, REALISTIC AND RISK-FREE
A restructured New Hospitals Programme is focused on a changing NHS estate and a deliverable programme over the next decade. Mark Shepherd, Director at MPA Precast and MPA Masonry explains where offsite manufacture, precast concrete and repeatable construction fits in.
CARBON RATINGS AND CALCULATORS
The Global Cement and Concrete Association announces the launch of Low Carbon Ratings for Cement and Concrete – a first-of-its-kind transparent global rating system and Milbank Concrete Products unveils its own Carbon Reduction Calculator for precast and prestressed concrete products.
AGGREGATE INDUSTRIES REBRANDS
Building solutions specialist Aggregate Industries has now fully rebranded to Holcim UK as part of a strategic shift to drive innovation and growth as a sustainable construction leader in the UK, with particular focus on decarbonisation and circularity.
BENEFITS OF PRECAST CONCRETE FOR DATA CENTRES
Data centres are critical to modern life and has FP McCann point out, offsite manufactured precast concrete plays a major role in overcoming the construction challenges facing this sector and ensuring that the UK does not fall behind in the technology race.
ROGER BULLIVANT PARTNERS WITH C3 CONSTRUCTION
Carried out in collaboration with C3 Construction, Roger Bullivant successfully installed a comprehensive precast foundation package solution for a residential development in Kettering, and used low-carbon concrete across all its precast products.
COMBILIFT UNVEILS SELF-PROPELLED INLOADER
Combilift unveiled its pioneering SelfPropelled Inloader COMBi-SPI at Bauma 2025. The highly anticipated launch marked a significant milestone in the transport of high loads including precast concrete panels.
HMP MILLSIKE OFFICIALLY OPENS
The award-winning HMP Millsike has officially opened. The UK’s first all-electric prison is the first prison in the UK to be delivered as part of the Alliance 4 New Prisons programme and showcases precast concrete at its best.
REPEATABLE, REALISTIC AND RISK-FREE
Repeatable construction using homegrown materials and offsite construction techniques are going to be key to derisking healthcare projects and delivery, says Mark Shepherd, Director at MPA Precast and MPA Masonry.
A restructured New Hospitals Programme is focused on a changing NHS estate and a deliverable programme over the next decade and when Wes Streeting, Secretary of State for Health & Social Care unveiled Labour’s revised New Hospitals Programme (NHP) earlier this year, he was quick to brand the previous administration’s programme target of 40 new hospital projects by 2030 as undeliverable.
Realistic delivery in a challenging fiscal environment means that the new programme is based on a new staged delivery timetable. Wave zero will see the delivery of projects which are already in the advanced stages of development completed within the next three years. Wave one will then follow with projects in construction
between 2025 and 2030 and waves two and three will be completed right up to 2039.
Prior to the NHP, each new hospital building would have been designed, developed and built as a standalone bespoke project for an NHS Trust. The programme is focused on standardisation, using the repeatability of designs to build better and faster as part of a co-ordinated national plan overseen by the Department of Health & Social Care and NHS England.
While the NHS programme is clearly not as ambitious on timescales as it once was, it is still competing for resources – people, materials and plant – at a time when infrastructure and housing pipelines are set to be significant over the next decade. Like
other sectors, it is also attempting to deliver a complex programme when global materials supply chains, particularly for imported steel, are unpredictable due to the impact of President Trump’s tariffs on the global economy.
Against this backdrop it’s important that the Government and NHS estate maximise the speed and repeatability of offsite construction and use component-led construction to reduce on-site labour and de-risk the delivery of the NHP programme. The revised programme also provides a major opportunity to retain as much economic value in the UK as possible.
Precast concrete is an established modern method of construction (MMC) offsite solution and is
PRECAST CONCRETE
increasingly playing a vital role in delivering high-quality, efficient healthcare buildings. Part of an essential UK concrete manufacturing sector, precast uses homegrown materials to reduce the demand for imports, ensure security of supply, while cutting carbon and protecting high skilled jobs.
Importantly, precast concrete components enable faster construction with minimal disruption which is crucial for live hospital environments but also repeatable hospital designs.
With consistent factory-controlled quality, precast elements provide excellent fire resistance, acoustic separation, and thermal performance, all of which are essential for patient safety, comfort, and operational efficiency.
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Although MMC is often associated with lightweight materials, precast concrete has long been established as a reliable MMC solution. The use of precast concrete panels for both floor and wall units has been proven over many years, offering significant benefits such as structural integrity, durability, fire resistance, and acoustic performance - often surpassing those of lightweight alternatives. Concrete is an inherently non-combustible material with the highest fire safety rating of class A1, reducing risk in a hospital environment.
From a health and safety perspective, construction workers can be better protected on MMC projects as its techniques reduce both the amount and scope of traditional on-site construction activities. The installation
AWARD WINNING PRECAST HEALTHCARE INNOVATION
of precast concrete has recently seen new innovations, including the use of air-inflated crash bags and nets to ensure that workers operate in the safest environment when fitting the precast elements.
The delivery of the newly revised NHP programme remains an ambitious plan but with new pragmatic timeframes. With standardised, high-quality designs it can be a blueprint for offsite delivery and an economic catalyst for the sector. Precast concrete has an important role in de-risking projects and delivering a new, modern NHS estate that’s fit for the future.
Images: 01-04. Precast concrete is a key MMC material to transform healthcare facilities.
Courtesy Techrete Ltd
During the COVID-19 pandemic, John Sisk & Son engaged Techrete to provide 348 precast concrete panels for the Rock Wing at Mater Misericordiae University Hospital in Dublin. Designed by Scott Tallon Walker Architects, the brief was to create a modern wing which would provide the hospital with occupancy for an additional 5,000 patients annually.
Techrete’s punch window panels incorporate a terracotta veneer, with an acid etched finish to the concrete elements and glazing which was installed at their facility in Dublin. The flat wall panels to the stair core feature concrete fins, echoing the solar shading provided by the window fins on the main elevations. Dummy joints to the top of the stair core provide an additional design feature. The hospital emblem was cast into the large wall panel to the main building entrance using a bespoke rubber mould.
The Rock Wing won both ‘Building of the Year (Medical and Health)’ at the Building and Architect Awards 2024 and the ‘Public Buildings and Infrastructure’ award at the RIAI Awards the same year, as well as ‘Healthcare Project of the Year’ at the 2025 Irish Building and Design Awards this spring in Dublin. Steven McGee, Chief Operating Officer, Sisk Ireland & UK said: “This is an amazing example of a value for money approach to speedily developing a healthcare asset in super quick time during the pandemic.”
For more information visit: www.mpaprecast.org
PRECAST CONCRETE
New Carbon Calculator Now Available
Milbank Concrete Products have launched a Carbon Reduction Calculator, a pioneering tool designed to provide accurate carbon savings data for precast and prestressed concrete products.
This innovative tool, developed in-house and in-line with Milbank’s ongoing commitment to sustainability, will be included as standard in all quotations from 2025, enabling architects, developers, and contractors to make informed, eco-conscious decisions from the outset of their projects.
Lee Cowen, Managing Director of Milbank Concrete Products, said: “Sustainability is at the heart of everything we do at Milbank. The launch of our Carbon Reduction Calculator places us at the forefront of the industry, offering customers the transparency they need to make informed, responsible decisions. As the demand for low-carbon construction solutions grows, we are proud to be leading the way with this innovative tool, helping our customers to actively reduce their environmental impact while maintaining the high quality and performance they expect from Milbank.”
World’s First Low Carbon Ratings System for Cement and Concrete
The Global Cement and Concrete Association (GCCA) has announced Low Carbon Ratings (LCR) for Cement and Concrete – a first-of-its-kind transparent global rating system that will enable cement and concrete to be identified based on their carbon footprints. The ratings system is designed to help customers prioritise sustainability when selecting construction materials by using a clear and intuitive AA to G scale.
Inspired by well-known appraising schemes such as the EU’s Energy Performance Certificates and the US Home Energy Rating System, the LCR offers a simple, transparent, and adaptable tool that helps builders, architects, governments, planners, and consumers everywhere in the world to make more informed and sustainable choices.
Thomas Guillot, Chief Executive of the GCCA, said: “Cement and concrete are the foundations of modern life – from the buildings we live and work in, to the roads we travel, and the infrastructure that supports clean water and green energy. As global demand for sustainable construction grows, the need for greater transparency around the carbon footprint of construction materials is more critical than ever.
The Milbank Carbon Reduction Calculator is a direct result of years of investment in sustainability. Using data calculated against our 2018 baseline, the tool reflects a range of significant improvements made across Milbank’s manufacturing processes.
Writing in a web blog David Costin, Innovation and Strategy Director said: “For the first time, our customers will receive data about how much CO2 they have saved by using Milbank products, alongside every quote, allowing them to evaluate the environmental impact of their chosen precast concrete solutions. This will help businesses and individuals meet sustainability goals, support environmental certifications, and comply with new carbon reporting requirements being introduced across the construction sector.
“By integrating carbon reduction calculations into the early planning and procurement stages, we are empowering decision-makers to prioritise sustainability without the need for additional research or calculations. This seamless approach ensures that low-carbon alternatives are not only available but are actively encouraged as part of the quoting process.
“We are actively exploring new materials, innovative low-carbon concrete, and further enhancements to production efficiency to drive down emissions even further. With the construction industry evolving rapidly, we are continuing to take a proactive role in reducing environmental impact while delivering the high-quality precast concrete solutions we are known for.”
Source: www.milbank.co.uk
“Our Low Carbon Ratings system supports more sustainable procurement practices and will empower the entire value chain to accelerate decarbonisation. With this rating system in place, governments, policymakers and the private sector can now prioritise lower carbon cement and concrete in the procurement process which will in turn further stimulate the industry’s focus on decarbonising these essential building materials.”
The ratings system is designed to be easily recognisable – with a simple visual graphic that clearly indicates a product’s rating. The carbon rating system for cement and concrete provides consistency and comparability. Countries can adopt the global ratings as they are or adapt them if local carbon accounting differs from global norms. With notable construction projects already demonstrating the use of lower carbon cement and concrete, the industry is making important progress. The launch of this global rating system marks another milestone on the road to greater sustainability.
Marlène Dance, Decarbonisation & Sustainable Design Expert, at Bouygues Bâtiment International said: “We believe a globally consistent carbon rating system—adopted by all countries and used by all concrete suppliers—would be a game changer. We see great value in a simple, user-friendly tool, tailored for construction teams. It will help empower our site crews to better understand and manage the carbon footprint of the concrete they use.”
The GCCA worked with the Clean Energy Ministerial Industrial Deep Decarbonisation Initiative (IDDI) and stakeholders to create a set of globally applicable definitions for concrete. These are ready to use in most countries. If a country has a different practice for product carbon accounting, then adaptation of the ratings can be done. This has already been completed in the UK. The GCCA cement and concrete ratings can be used with national and local baselines and targets to support low carbon procurement.
Source: www.gccassociation.org
PRECAST CONCRETE
Aggregate Industries Rebrands
Building solutions specialist Aggregate Industries has rebranded to Holcim UK as part of a strategic shift to drive innovation and growth as a sustainable construction leader in the UK. Holcim UK’s strategy will see the organisation target significant growth in sales and sustainability – with particular focus on decarbonisation, circularity and nature – aiming to facilitate continued investment in its people, products and solutions.
Alongside a target to accelerate green growth, Holcim UK is committed to expanding the uptake of sustainable building materials in the UK. Currently a third of its turnover comes from sustainable products and it is aiming to continue to increase this in the next five years. With over 200 sites and 4,000 employees across the UK, the organisation’s 25 brands are uniting under Holcim UK to drive this growth. Building on trusted partnerships, the move is also set to provide customers with access to more seamless, enhanced services and sustainable solutions.
The consolidation comes as the UK construction industry faces increasing pressure to deliver more homes and buildings in line with emissions reduction
and environmental policy, amid predicted growth of up to 10% by 2026. To support customers with delivering projects quickly and sustainably, the newly unified Holcim UK is focused on developing strategic partnerships that provide customers with access to all product ranges for their projects across the UK.
Following 20 years as a UK-based subsidiary of Holcim Group, the new direction sees the business align more closely with its Swiss-based parent company, which operates across 70 countries and employs over 60,000 people worldwide. Holcim UK will leverage global insights, innovation and expertise in sustainable solutions from Holcim Group to enhance the business’s existing rich UK heritage and its understanding of the local market.
This presence in the UK market has already seen the launch of product ranges such as ECOPact low carbon readymix concrete, ECOPlanet range of low carbon cement, and its ECOCycle range of products, which are made from at least 10% recycled materials
This focus on circularity is underpinned by continued investment, including recent acquisitions of CDM specialist companies Land Recovery and Sivyer, in addition to innovations such as neustark – the technology which permanently locks carbon removed from the atmosphere into processed demolished concrete for new products.
Holcim UK’s strategy centres around its mission to make sustainable construction a reality, focusing on decarbonisation, nature, circularity and innovation. Its
aim is to achieve this through both its commitment to reducing its own impact on communities and the planet.
Lee Sleight, CEO of Holcim UK, said: “Our evolution from Aggregate Industries to Holcim UK is much more than a rebrand. It represents a commitment to leading the construction sector towards a more sustainable future through a commitment to innovation and collaboration.
“We are the same people with the same products and solutions that our customers have trusted over the years. But by uniting under one coherent brand, we have a renewed opportunity to drive more sustainable growth for our business and the many customers and suppliers we have formed strong partnerships with over the years.
"With such growth, we can continue to invest in the people and solutions capable of making a positive difference to customers and communities. Key to this will be our ongoing prioritisation of people, purpose and performance to achieve our ambitious revenue and sustainability growth targets. Through taking on the global brand, we can leverage Holcim Group’s global presence and the innovative solutions it has brought to a variety of different markets. With our renewed strategic direction, we will not only be able to reduce our environmental impact and make positive change as a business but be a trusted partner to our customers as they aim to do the same.”
Source: www.holcim.co.uk
PRECAST CONCRETE
Unique HS2 Tunnel Portal Completed
Contractors building HS2 have completed work on a pair of innovative extensions to the southern portal of its longest tunnel to eliminate the possibility of ‘sonic boom’ being created by high-speed trains entering at 200mph. The structures, built at the southern end of the railway's 10-mile Chiltern Tunnel to the north-west of London, are near identical to those now under construction at its northern portal in Buckinghamshire.
All trains entering tunnels anywhere in the world force air forward, creating pulses of energy that roll along the tunnel causing a small release of air pressure into the outside world at the far end. Known scientifically as ‘micro pressure waves’, they are inaudible on conventional railways. But in high-speed rail tunnels, air shoved forward without escape routes can create powerful pressure waves that emerge as an audible ‘thud’ or ‘sonic boom’.
In a first for the UK rail network, HS2’s design includes extensions on all eight tunnels where trains enter at speeds above 140mph. However, the length, physical setting and aesthetic of those at each end of the line’s tunnel beneath the Chiltern Hills mark them out as unique even to HS2.
HS2 Ltd chief engineer, Mark Howard explains: “The maximum speed of HS2 varies along the route. But where the train is entering a tunnel travelling above 140mph we are building portal extensions to prevent
‘sonic boom’ occurring. Although there are several tunnels on the line where train speed will be higher than in the Chiltern Tunnel, no other combines speeds of 200mph with length of 10 miles. Its these unique physical characteristics that demand unique structures at each end.”
First identified in 1974 during train testing on Japan’s then new 187mph ‘Sanyo’ shinkansen line, when people nearby noticed ‘booms’ near tunnel exits, the problem was solved by the invention of perforated portals extending from the tunnel entrance. Building on over 40 years of research by the international rail community, the engineering team from HS2 Ltd, engineering consultancy Arup together with the University of Birmingham and Dundee Tunnel Research, developed and laboratory-tested HS2’s tunnel portal design.
To mitigate against ‘sonic boom’ HS2’s tunnel beneath the Chiltern Hills requires bespoke portal extensions. Protruding up to 220 metres – around the length of two full-size football pitches – from a chalky cutting near the M25 motorway, they are each punctuated along one side with ventilation portholes. These enable some air pushed forward by the train to escape, making the pressure increase more gradual so that the micro-pressure wave emitted from the other end of the tunnel is undetectable.
In order to decide how long each extension needed to be for every HS2 tunnel, the team used micropressure wave measurements from Britain’s first high speed line between London and the Channel Tunnel, HS1 as the benchmark. The line’s tunnels do not experience sonic boom because the micro pressure waves are too weak. Therefore HS2’s research team used it as the basis to develop anti-sonic boom porous tunnel extensions for the new London-West Midlands high speed line.
Arup Fellow Richard Sturt said: “Arup is proud to have helped create a new international benchmark for the suppression of sonic booms with the HS2 tunnel portals. They are longer than any existing portals anywhere else in the world as we have prioritized seating capacity on the train, avoiding the need for a long nose section on the train like the Japanese shinkansen. The portals’ unique tapered design combined with the precision-sized holes provide an incredibly smooth build-up of pressure as the train enters the tunnel. As a result, there won’t be any audible noises from micro pressure waves, despite the extremely high train speeds.”
Source: www.hs2.org.uk
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BENEFITS OF PRECAST CONCRETE FOR DATA CENTRES
The data centre sector is experiencing exponential growth globally as new technologies, increasingly driven by artificial intelligence and machine learning, demand a significant increase in capacity. How does precast concrete fit into this shift?
The pace of development for these technologies is so rapid that time is of the essence. A failure to meet the urgent demand for data centres could hold back businesses and stifle the UK’s economic growth. This underscores the crucial role of data centre developers, engineers, architects, and industry stakeholders in ensuring the timely construction of these facilities. Offsite manufactured precast concrete is playing a major role in helping to overcome the construction challenges facing this sector, ensuring that the UK does not fall behind in this technology race.
Thermal mass to regulate internal temperatures
Data centres are critical to modern life. They are buildings containing banks of computers that power everything from
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the internet, AI, cryptocurrency, and streaming to our data storage cloud services. Concrete, being a dense material, possesses a property known as 'thermal mass’. This means it can absorb and store a significant amount of heat, which helps maintain a stable temperature inside the building. This not only reduces the need for artificial cooling systems but also saves energy and improves comfort.
Optimisation for fast-track construction
Precast concrete was one of the original modern methods of construction (MMC), long before the term was coined. Hence, FP McCann undertakes numerous Design for Manufacture and Assembly (DfMA) projects across the UK and Ireland, including data centre construction.
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Products are manufactured in a factory environment, where quality consistency can be carefully maintained, and then delivered to the site for installation. This process can complete projects 25% to 50% quicker than traditional building methods. The speed of construction can be maximised by choosing precast concrete solutions for key building elements, such as lift shafts and walling, as well as for the primary structural framing.
Standardised and customisable precast components also enhance the efficiency and scalability of data centres, and modular precast designs are beneficial in enabling the future expansion of data centres. Additionally, choosing precast can also mean reduced disruption to the
LOW CARBON PRECAST FOUNDATION SYSTEMS
RBL's precast ground beam system, RBeam, is developed in-house and manufactured to factory standards, offering a superior alternative to traditional in-situ ground beams.
LOW CARBON CONCRETE
RBL’s precast system saves between 2 and 5 tonnes of CO e per plot in comparison to insitu foundations.
This ensures a precise, consistent precast system, supported by readily available stock beams.
The system includes design, manufacture, setting out, and installation, ensuring a fast and efficient construction process.
PRECAST CONCRETE
site and surrounding areas, as fewer delivery vehicles may be needed to transport construction products to the site. This is also a sustainability benefit.
Easing the skills shortage
Another significant benefit of precast products being made offsite is that they can be assembled with relative ease on-site. Using precast concrete instead of other approaches, such as brick and block or metal cladding and roofing, reduces the number of trades needed on-site. This is a significant advantage given the national skills shortage affecting the construction industry.
High security and fire safety
Given the critically important, high profile role data centres play in our national infrastructure, they are a target for terrorism – hence their design requires sandwich cladding from the ground to a height of 3.5m. Precast
walling can be used here to provide a high-strength solution that is robust enough to resist the impact of such attacks.
Precast concrete also offers a high level of resistance to fire compared to other materials. This is a critical consideration for data centres, given the presence of extensive electrical equipment and networked systems. FP McCann can even cast conduits into the precast concrete floor and roof products to reduce reliance on plastic conduits, which are more vulnerable to fire.
Structural and load-bearing benefits to accommodate heavy
loads
The strength of precast concrete is also more suitable for accommodating the weight of the technology packed into data centres. Choosing precast concrete flooring, such as beam and block or hollowcore planks, is very
effective at accommodating heavy equipment loads, raised access floors, and cooling systems, among other structural objectives. Precast flooring panels can also span significantly further than many other materials, which can result in fewer structural columns being needed. This increases the versatility of internal spaces, allowing them to be reconfigured more efficiently throughout the data centre's operational life.
A sustainable material choice
The sustainability credentials of precast concrete also enable developers to meet stringent targets related to embodied carbon and whole-life carbon emissions, aligning with globally recognised sustainable building standards such as BREEAM and LEED. The processes used by FP McCann for manufacturing, for example, are designed to optimise resource and energy efficiency, including through recovery and recycling initiatives. The result is a product with an exceptionally long lifespan, manufactured most efficiently. In addition, FP McCann’s design team is accredited to BIM Level 2. By integrating BIM throughout the design and construction process, they can support carbon footprint analysis and material optimisation.
How FP McCann supports data centre developers, engineers and architects
FP McCann’s in-house designers are highly experienced, skilled and resourced to add significant value throughout the design and construction of data centres. The broader FP McCann team is structured to deliver comprehensive end-to-end design and engineering support, providing assistance from early concept design to installation, to ensure seamless project execution. For example, custom detailing can be developed for complex layouts and equipment-heavy zones, and realtime updates to models can be done to accommodate late-stage design changes. It all adds up to a more efficient construction process, enabling the rapid delivery of data centres.
For more information visit: www.fpmccann.co.uk
Images: 01-04. Precast concrete is an ideal offsite approach to providing secure surroundings for critical infrastructure such as data centres
PRECAST CONCRETE
Roger Bullivant Partners with C3 Construction
Roger Bullivant Limited (RBL), a leading specialist in foundation solutions, has successfully installed a comprehensive precast foundation package solution for a residential development in Kettering. The project was carried out in collaboration with ground works specialist, C3 Construction, showcasing the benefits of a streamlined partnership to deliver quality and cost-effective results for the client.
The development consists of 72 residential plots and 21 garages, all completed within a single construction phase. RBL installed Driven Precast Concrete Piles capable of accommodating the required compressive, horizontal, and heave forces on the scheme. The piles were driven to an average length of 10m, penetrating through made ground and into the underlying clay. This approach was selected to meet the specific ground conditions of the site, ensuring a stable and durable foundation solution.
RBL delivered a complex and efficient foundation solution for this project, utilising both precast RBeam and bespoke cast-on-site ground beams for
different site conditions. Completing the entire the full foundation package in 20 weeks.
Sustainability was also a key consideration during the project. RBL utilised low-carbon concrete across all precast products. This specialist concrete mix reduces the carbon footprint without compromising on durability or strength and is designed and specified to ensure enhanced performance that is suitable under different conditions, making it robust and durable enough for a variety of soil types allowing the beams to perform in challenging environments. This solution also significantly reduces waste on site – its ‘kit of parts’ approach means fewer materials are needed and less gets wasted during construction.
All RBeam designs are optimised though selection of fit for purpose solutions from our range of standardised manufactured foundation beams and components that form part of the RBeam system. This ensures efficient cost-effective use materials specified without compromising on project specific requirements.
Collaboration with C3 Construction played a key role in the success of this project. By working closely from the outset, both parties agreed on working platform levels early in the process, allowing time for the recovery of the stone piling platform. This seamless coordination not only reduced costs for the end client but also ensured the project remained on schedule while maintaining the highest quality standards.
Commenting on the project, Luke Taylor, RBL's Regional Operations Manager, said: “The success of this project highlights the value of a strong partnership with C3 Construction. Their proactive approach and expertise in groundworking enabled us to coordinate seamlessly, reducing delays and ensuring the foundations were completed to the highest standards.”
Source: www.roger-bullivant.co.uk
PRECAST CONCRETE
Combilift Unveils
Self-Propelled Inloader
Combilift recently unveiled its pioneering SelfPropelled Inloader COMBi-SPI at Bauma 2025. This highly anticipated launch marked a significant milestone in the transport of high loads, such as precast concrete, wall panels or glass A-frames, within production facilities and yard environments.
Development of the COMBi-SPI began in April 2022, driven by the need for an efficient, manoeuvrable, and cost-effective alternative to expensive trailers and trucks. The objective was clear: to create a versatile solution capable of handling 30-tonne loads on industry standard Inloader Pallets with superior visibility, agility, and ease of operation.
The collaboration with Spaansen, a specialist in precast concrete, influenced the design through to the final stages. Early prototypes focused on reducing overall length and width and enhancing manoeuvrability for working in busy production facilities. However, the project took a significant turn when Spaansen opted for a fully electric model middevelopment. This shift required a complete redesign to integrate the electric wheel motors as well as fit the
interchangeable batteries into the legs of the machine. Advanced features include:
• Side-Facing Cab: Provides operators with a clear view of both the load and direction of travel, ensuring enhanced safety and precision
• Sliding Load Supports: Adjustable supports along the chassis to accommodate various load lengths and heights during travel
• Pivoting Front Dual-Wheel Configuration: Eliminates the need for suspension, optimises stability and gives a tighter turning circle
• 300mm Ground Clearance: Designed for both concrete and gravel yards, offering reliability across diverse work environments
• Power Options: Available in Electric (with interchangeable battery system), Diesel, and LPG, catering to different operational needs
• Large Solid Tires for durability and yard maintenance
• Compact Yet Powerful: The short chassis enhances load support, maintains a low centre of gravity and offers more manoeuvrability, especially while operating within production facilities.
With unmatched manoeuvrability and faster operational speed, the Self-Propelled Inloader transforms yard-based logistics by eliminating the reliance on multiple trailers and shunters, significantly enhancing efficiency and reducing operational costs for businesses handling oversized, high loads.
“This project showcases Combilift’s commitment to innovation and customer-driven design,” said Josh Moffett - Heavy Equipment Manager at Combilift.
“We’ve leveraged decades of expertise in specialised transport machinery to develop a state-of-theart solution that meets the evolving needs of the concrete and glass industries.”
Source: www.combilift.com/spi
Kier Delivers HMP Millsike
The award-winning HMP Millsike was officially opened on 28 March by Lord Chancellor and Secretary of State for Justice, Rt. Hon Shabana Mahmood MP, and Minister of State for Prisons, Probation and Reducing Reoffending, Lord Timpson OBE.
Showcasing precast concrete technology, HMP Millsike is a Category C prison and has a capacity of around 1500. It is the UK’s first all-electric prison and is the first prison in the UK that has been delivered as part of an alliance, the Alliance 4 New Prisons (A4NP). The Ministry of Justice will deliver 20,000 new prison places overall, with the A4NP delivering 6000 of those. Building on the work Kier did at HMP Five Wells, this model allows the members of the alliance to focus on repeatability and continuous improvement to drive better performance in capital delivery and lifecycle costs.
The project used 14,550 precast concrete components and circa 90,000 subcomponents manufactured across nine factories. DfMA played a huge role in the construction of HMP Millsike with PCE Ltd’s award winning HybriDfMA Secure Prison System being used following the successful completion of HMP Five Wells, at Wellingborough and HMP Fosse Way, Glen Parva. HMP Millsike runs solely on electricity, making it the first of its kind in the UK, with more than 8,500kwh of renewable energy
being generated to power it. Solar panels, heat pump technology and more efficient lighting systems mean that it will use approximately a quarter of the energy used to heat traditional Victorian prisons.
Kier’s Strategic Projects team worked collaboratively with in-house mechanical, electrical, and plumbing (MEP) experts to manage the vast and complex MEP installations. Innovative digital processes and programmes were used to deliver HMP Millsike, including OpenBIM and digital standardisation. Led by Kier, the digital construction process provided a trackable and accurate build process throughout delivery – from design and manufacture through to installation. Digital platform, Ynomia, was used to generate a 3D digital twin to visualise every component, ensuring the use and performance of each one was monitored in real time during the build, saving considerable time and money.
Stuart Togwell, Group Managing Director at Kier Construction, said: "Using our significant experience in the justice sector, Kier has delivered a state-ofthe-art, carbon-efficient facility designed to support
rehabilitation, which has also provided new jobs, economic investment and skills development for the surrounding communities.”
Rt. Hon Shabana Mahmood MP, Lord Chancellor and Secretary of State for Justice, added: HMP Millsike sets the standard for the jails of the future, with cutting crime built into its very fabric. It is a huge step in our plan to add 14,000 extra prison places by 2031. But building jails only takes us so far in ending this crisis, which is why we’re also reviewing sentencing so we can always lock up dangerous offenders and make our streets safer."
Kier has extensive experience delivering justice projects, including the multi award-winning HMP Five Wells in Wellingborough, utilising an innovative houseblock design that was manufactured offsite, which was also replicated at HMP Millsike. HMP Millsike was procured via the Crown Commercial Services - Construction Works and Associated Services framework.
Source: www.kier.co.uk
OFFSITE EXPO brings together those who are driving change in the construction sector – the event will play host to the leading UK and international offsite manufacturers and component suppliers showcasing a broad spectrum of panelised and volumetric modular systems, plus pod and prefabricated MEP solutions.
