Home Case Studies

Case Studies

Brentford Care Home, UK

Client: Housing 21 and Inspace Location: Brentford, West London
brentford-care-home
Project Size:
4600m² - 5-storey
Build Time:
12 weeks

Info

Fusion cassettes, with large ground floor transfer structure to open areas. A very tight site.

Meadowside Care Home, UK

Client: Catalyst Location: London
meadow-care-home
Contractor / Developer:
Willmott Dixon
Project Size:
4,000m²
Build Time:
Completed in 14 weeks

Info

This 4 storey Extra Care Home incorporates significant hot rolled steel transfer structures. Client has benefited from absence of post construction shrinkage.

Duval Care Home

Client: Circle Anglia and Inspace Location: Islington, London
duval
Project Size:
3,250m² - 4-storey
Build Time:
11 weeks

Info

Fusion cassettes, with integrated hot rolled steel to large open areas of ground floor. Structural bathroom pods manufactured and installed by Fusion. Very tight site.

Brightwell Court Care Home, UK

Client: Circle Anglia Location: London
brightwell
Contractor / Developer:
Willmott Dixon
Project Size:
3,500m² - 4 storey
Build Time:
13 weeks

Info

This Extra Care Home incorporates significant hot rolled steel transfer structures above ground floor.

The client has benefited from absence of post construction shrinkage.

The use of the Fusion system meant brickwork was started before tiling of the roof, as were some internal works, allowing Willmott Dixon to significantly reduce their overall construction period.

Addlestone One – town centre regeneration

Location: Addlestone, Surrey
Addlestone
Contractor / Developer:
Bouygues
Project Size:
Six apartment buildings
Build Time:
12 months

Info

The project: Addlestone One is a £90m mixed-use town centre regeneration scheme led by Runnymede Borough Council. Bouygues was appointed in November 2012 to develop the Council’s aspiration for new shops, leisure facilities, homes and public spaces which would aim to create a vibrant environment for people to work, visit and live. The project is due for completion in October 2017.

The brief: The residential element of the scheme, six apartment buildings, had originally been designed as a timber frame structure. However due to budget constraints and concerns over fire safety, Bouygues needed to find another option.

The solution: Bouygues reviewed concrete and light gauge steel as alternative building materials before concluding that Fusion’s pre-insulated system would be the most suitable option

Our design team worked closely with Bouygues to adapt the original timber frame designs, taking care to retain the architectural integrity of the buildings.  We used our patented frame insulation system to ensure the apartments were insulated to 0.2W/m2K without any further materials needing to be installed on site. All M&E positions were pre-cut into the insulated frames, making installation for other trades as easy as possible, and we were able to adapt our design to cater for masonry above a height of 12m, something which is not normally possible when working with a light gauge steel system.

Challenges faced: The Addlestone site was extremely busy with so many elements of the scheme coming together at the same time. Access was tight and with a school located opposite, there were further restrictions over vehicle movements. But, by integrating our team with Bouygues early in the supply chain, we were able to deliver exactly the right product to site, using five or six times fewer vehicle loads than traditional build methods, produce little or no wastage, and have no more than 10 personnel on site at any one time. We provided Bouygues with predictability and reliability throughout the build.

Customer comment: “Fusion was a reliable partner throughout the Addlestone One project. The whole team worked extremely well together and from experience, they knew the ideas they were proposing would work. We made the right decision switching from timber to light gauge steel and I’m excited to explore ways in which Fusion can be part of our plans in the future.”

Simon Phipps, Regional Production Director Bouygues Housing South East

Angmering, West Sussex

Location: West Sussex
Trial properties 5
Contractor / Developer:
Barratt Developments
Project Size:
Trial
Build Time:
9 weeks

Info

The project: Barratt Developments has set a strategic goal to produce at least 20% of its output using offsite methods by 2020. Over a two-year period the developer evaluated 150 different offsite businesses and as part of the process, wanted to run a trial project to see how this approach could potentially scale up for volume housebuilding.

The brief: In 2015, Barratt asked Fusion to design, manufacture and erect light gauge steel superstructures for domestic properties at its Swanbourne Park development in West Sussex.

The solution: The project required integration from the very start of the supply chain – personnel at all levels at both businesses needed to be fully engaged and appreciate what the trial could mean for the future of housebuilding in the UK.

Existing housing designs were adapted to incorporate the light gauge steel superstructure, and in addition to meetings held with senior management, Fusion
took the time to fully brief Barratt site teams on the Fusion system. In late 2015, the project was ready to start on site and with just five men, in nine days, nine properties had been erected.

“If you can get that amount of structure built in nine days in November, why on earth would you do anything else?” Carpenter at Angmering on the Fusion offsite trial project.

The trial was deemed a success. The experience gained from this has
secured an offsite order book with Barratt currently worth over £3million – this covers some 160 houses and six apartment blocks, located across three different sites.

Customer comment: Oliver Novakovic, Barratt Developments’ technical and innovations director, said: “Offsite construction is high on our agenda and if we’re to meet our 2020 target, we
need to find the right technologies and partners to help us deliver the quality homes our customers expect.

“Our trial working with Fusion was a success. We were impressed with each stage of the process from design through to delivery and assembly on site. And now, as we’re about to embark on live, large scale developments with Fusion, I’m confident they can deliver, offering the business a further alternative to both traditional brick and block construction, and timber frame.”

 

 

The Old Oak, Ealing, North London

Location: Old Oak, Ealing, North London
Old Oak
Contractor / Developer:
Mace
Project Size:
12,000m2
Build Time:
21 weeks

Info

The project:The Old Oak in Ealing, North London is a new building complex offering a different kind of accommodation aimed at ‘millennials’, mixing small private spaces with quirky shared spaces. Called ‘The Collective’ it has 550 bedrooms and communal areas that include a spa, restaurant, games room, library and roof-top with plastic igloos – with most bills included in the rental price.

The brief: The project was briefed and designed as two buildings adjacent to each other – one seven storey structure and one nine storey, positioned on top of a transfer platform.

The solution: It was only fitting that a modern way of living should be built using modern methods of construction and Fusion was appointed to design and manufacture light gauge steel frames for an apartment block totaling 11 storeys within the development.

The Fusion team maximised the speed of build by applying weather proofing to specific floors of the structure, enabling other trades to maintain a good pace on site. The building was complete within 21 weeks. It is also first light gauge steel building to exceed the 30m two-hour fire mark and is believed to be the single largest steel structure of its kind in the UK.

Challenges: Part way through the project, the main contractor went into administration leaving Fusion in a position where it needed transition to new contractor Mace, whilst still working to complete the project on time.

Customer comment: Stephen Pycroft, Mace executive chairman, said: “Mace stepped into the breach on The Collective, Old Oak, when the original main contractor went into administration. We had to pick the job up at a late stage when the building was already in full flow, so the inherent risks were large and we needed a team around us we could rely on.

“Fusion was already on site when we started and the transition to working with the Mace team was seamless. During the course of the project they continued to excel, maintaining the programme and completing their works to an excellent standard.

“Though a tough start, the project wouldn’t have been the success it was without the support of the Fusion team.”

Ascalon Street

Client: A2 Dominion Location: Battersea, South London
IMG-20130325-00206
Contractor / Developer:
Kingsbury Construction
Project Size:
2,100m²

Info

A 4 storey block of apartments (2,100m2) on a very tight site in Battersea, South London. The scheme had to overcome the acoustic challenges of being built within 5m of a main commuter railway line. Fusion’s works were completed in 9 weeks.

Riverside Apartments, Cambridge, UK

Location: Cambridge
riverside-cambridge
Project Size:
77 apartments, on concrete transfer slab.

Info

Significant quantities of hot rolled steel incorporated into the design. Extensive use of lightweight external cladding system – terracotta tiles and render.

Stockwell Court Luxury Homes, UK

Client: Mace Living Location: South London
stockwell-court-homes
Contractor / Developer:
Mace Living
Project Size:
11 no. large units
Build Time:
10 weeks

Info

Units include a basement

Scott House Apartments, UK

Client: Willmott Dixon Location: Islington, North London
scott-house-apartments
Project Size:
2,500m²
Build Time:
10-weeks

Info

Included infill panels to ground floor.

Kingston Heights Phase 1

Client: Affinity Sutton Location: Kingston-Upon-Thames
13-2-13 116
Contractor / Developer:
United House
Project Size:
3,500m²
Build Time:
10 weeks

Info

Fusion’s structure commences at 4th floor level and partly lies above a large electricity sub-station. Fusion’s works have involved forming a sub-floor on stub walls above the sub-station to create acoustic/vibration isolation with a further 3 storeys of Fusion structure (3,500m²). Fusion’s works were completed in 10 weeks.

Bagley’s Lane, UK

Location: Chelsea, London
bagley-lane-uk
Project Size:
6000m²
Build Time:
15-20 weeks

Info

£1.15m scheme, private flats, 90 odd flats @ approx £400,000 each

Allwoodley Apartments, UK

Client: Persimmon Location: Leeds
allwoodley-apartments
Project Size:
2,200m²
Build Time:
8 weeks

Info

Incorporated complex timber roofs

Queen Victoria Hospital

Location: East Grinstead, West Sussex
awaiting-image
Project Size:
882m²
Build Time:
7 weeks

Info

Fusion’s pre-insulated external wall system to ground floor, un-insulated walls to roof plant enclosure, internal load-bearing walls and hot rolled steel

Bannister Primary School

Location: Southampton
bannister-primary-school
Contractor / Developer:
Willmott Dixon
Project Size:
2,783m²
Build Time:
9 weeks

Info

Hybrid Fusion and hot rolled steel structures with composite metal deck/concrete floors and roofs

Wordsworth Primary School

Location: Southampton
wordsworth-primary-school
Contractor / Developer:
Willmott Dixon
Project Size:
1,870m²
Build Time:
11 weeks

Info

Hybrid Fusion and hot rolled steel structures with composite metal deck/concrete floors and roofs

Angel School Townhouses & Apts

Client: Places for People Location: London
angel-school-townhouse
Contractor / Developer:
Wates
Project Size:
3,600m² – Ten 3 storey townhouses and 25 apartments

Info

Designed to match surrounding properties. Tight inner city site.

Sheraton Fota Island Hotel & Spa

Client: John Fleming Construction Location: Fota Island Resort, Cobh, Co. Cork
sheraton-island-hotel-spa
Project Size:
6,500m²
Build Time:
25 weeks

Info

Located on the scenic Fota Island Resort in Cork Harbour the faceted structure of the Five Star Sheraton Hotel and Spa is comprised of Fusion steel frame.

Merton Lodge Hotel, London

Location: London
merton-lodge-london
Project Size:
3,500m²

Info

A 4-storey hotel on 3 storey concrete structure by Wates for Premier Lodge.

Lightweight rain-screen cladding system

Lillie House

Location: Leicester
Screen Shot 2017-06-27 at 17.05.21
Contractor / Developer:
J A Ball Ltd
Project Size:
£700K
Build Time:
9.5 weeks

Info

The project: New student accommodation was planned for the landmark Lillie House site on London Road. Leicestershire-based contractor J A Ball had been awarded the work and from starting on site in February 2017, was tasked with completion ready for student intake within just seven months.

The brief: To design, manufacture, deliver and install a Fusion insulated light gauge steel superstructure for a seven-storey student accommodation block. Retail space would occupy the ground floor (constructed by others from reinforced concrete slab) and 138 units needed to be arranged over the six floors above, comprising a mix of bedrooms, apartments and studio accommodation.

Challenges faced: Build time and site access were significant challenges for this project. The Client wanted our works complete within 10 weeks, but our initial proposal was 16. Access to the site was also an issue being via a tight inner city network of one way streets – and a further challenge was faced when an area planned for Fusion trailers to be off-loaded became unavailable at the last minute.

The solution: We overcame the speed of build issue for our Client by developing a robust design which ensured we used product which was available, could be delivered on time and could be swiftly erected by our most experienced installers. We also used a ‘per level’ sign-off procedure. This meant each floor was completed in its entirety before being certified, negating the need for return visits and reducing timescales further.

The challenges faced with logistics were managed and resolved by effective communication and planning both internally and with our Client.

Customer comment: “We’ve worked with Fusion before so knew their system and capabilities. The reason we contracted them for Lillie House was down to the design of the building – uniform and stacked, and because we needed a fast build. If we were to meet the University’s deadline, our priority was to get into the building as quickly as possible. But thanks to Fusion working out a more time-efficient delivery programme, we were inside within 10 weeks – less than half way through the total build.”

Adam Ball, Director, J A Ball Ltd

www.jaballltd.co.uk

Cathedral Road, Derby

Client: The University of Derby Location: Derby
Queen St Elevation of Cathedral Road student accommodation, University of Derby
Contractor / Developer:
D W Hicks
Project Size:
£14m
Build Time:
20 weeks

Info

The project: New accommodation had been approved for the University of Derby at a prestigious location in the city’s Cathedral Quarter. Contractor D W Hicks had been awarded the work – a £14m 350-bed scheme to be ready for the start of the 2016 autumn term.

The brief: A seven-storey accommodation block, serviced by lifts and with 350 rooms arranged in a six-bed cluster layout comprising ensuite rooms, communal lounge and kitchen.

It was a fast-track project which wouldn’t allow for the build times associated with traditional methods, so Hicks had to turn to offsite options.

The solution: After researching the market, following up referral leads and a factory visit, Fusion’s light gauge steel system was chosen for the project. Within just 20 weeks, Fusion’s entire process was complete – from order to erection on site. This neat, predictable timeline slotted easily into the overall build programme for the project, and resulted in the development being completed two months ahead of schedule. Handover to the University was in August 2016.

Customer comment: “We were originally planning Cathedral Road with traditional methods in mind, but time and cost constraints simply didn’t allow for it. So, this was the first time we’d worked with Fusion and based on many factors which contributed to the success of this project, we now have two further student accommodation projects underway with them, worth £48million.

“A great deal of our work is in the student market and in my opinion, offsite is the only way forward.”

Martyn Hicks – Director, D W Hicks

Aberystwyth University

Location: Aberystwyth
Aberystwyth University Student Halls built with the Fusion Building System.
Contractor / Developer:
Cowlin (Balfour Beatty)
Project Size:
29,000m²
Build Time:
50 weeks

Info

The Penglais Farm Project at Aberystwyth involves the construction of 50 number linked blocks of 3 storey accommodation providing a total of 1000 bedrooms (29,000m2). Fusion’s scope of supply includes the supply and fitting of truss roofs and fitting of HRS stairs.

Oxford University

Location: Oxford
oxford-new
Contractor / Developer:
Longcross
Project Size:
13,281m²
Build Time:
14 weeks

Info

312 high-quality apartments for post-graduate students, with 8 blocks on an extremely challenging site. Restricted access to the site, which is narrow and bound on one side by the main railway line, necessitated the need for stringent sound performance ideally suited to Fusion’s flexible solutions.

Shane Kelly, Research and Development Manager, Longcross said “Longcross utilised the Fusion system on a large student accommodation development in Oxford for Oxford University Estates Division. We first came across the Fusion team and the system in early 2012 when sourcing an alternative build system.

There were a number of reasons why we had to research the market for an alternative build system but it was mainly the severe budgetary constraints and the high performance requirements of our client. Fusion proved to be the ideal partner for both these reasons.

From day one, the team at Fusion were extremely proactive and were able to commence design, manufacture and delivery within our original programme, despite a number of weeks being lost whilst researching an alternative system and more importantly Fusion were able to alleviate any concerns the design team and client had on utilising a new innovative system.

Fusion provided an alternative lightweight superstructure solution that was within budget for the scheme. In addition, the add-on benefits of the system meant that we were able to significantly reduce the foundations to the scheme and also absorb programme delays due to late design (from our consultants) without compromising our agreed PC date with the client. Fusion adopted structural design responsibility for the above ground structure and were able to deliver this without delay working in conjunction with a consultant team who had no experience of the system and delivered the first panels to site in just 11 weeks. This challenge in particular was no mean feat, and Fusion’s ability to adopt, inform and deliver is commended.

Additionally, the off-site nature of the Fusion system meant that we were also able to improve on site quality, significantly reduce transportation to site and also achieve waste targets way in excess of our original expectations.

Mitigating the risk was extremely important to both us and our client and Fusion were able to provide us with an off-site testing facility. This allowed us to prove the design and buildability of interfaces as well as acoustically test details prior to their construction on site. This mitigated a lot of risk for us and again showed the willingness of Fusion to go the extra mile in order to ensure that their system achieved the strict Building Regulation and BREEAM standards that the scheme required. One of the concerns of the client in changing from concrete to LGS was the noise from external sources as well as adjacent rooms. Fusion was able to alleviate these concerns through their rigorous testing regime which not only worked on paper but allowed the client to see the robustness of the detailing. Tests undertaken on the unit include party wall acoustic testing, floor acoustic testing, socket penetration acoustic testing, external wall (including several cladding systems) acoustic testing and window/glazing acoustic testing.

Despite the initial delay in design on the concrete frame, adopting the Fusion system ensured we maintained the original programme and we were able to erect eight 4/5 storey blocks in a little under 14 weeks including the roofs (to ply finish) which Fusion willingly took on for the final seven blocks again improving on site productivity.

The proactive culture of the Fusion team as well as their ability to deliver both on site and a product that meets stringent performance requirements has meant that Longcross are continuing to develop this excellent working relationship and hope to continue working with Fusion on numerous projects in the future.”

 

Horton Halls

Client: Willmott Dixon Location: Tooting
horton-halls
Contractor / Developer:
Willmott Dixon
Project Size:
10,000m², 350 bedrooms
Build Time:
12 weeks

Info

4 storey block, with cassette floors including flat roof with parapets.

Mark Peasey, Operations Director, Willmott Dixon said ‘The working relationship between Fusion and Willmott Dixon was positive throughout the build and meant the superstructure was completed ahead of programme despite poor weather conditions. The Fusion team were exceptional and their proactive attitude to the build programme and assistance to other trades was refreshing and bodes well for future projects between our companies. ’

Mike Fairey, Director, Fusion said ‘The success of this project reinforces Fusion’s belief that working hand in hand with our clients’ design team delivers projects on time and on budget. Fusion has a fantastic reputation in the student accommodation environment and the completion of this project continues to strengthen our position as a leading supplier of quality building solutions.’

Reading University

Location: Reading
reading-uni
Contractor / Developer:
Brookfield Multiplex
Project Size:
2,240m²
Build Time:
10 weeks

Info

3no. 192 beds, blocks of 4 storey townhouses, including concrete stairs

Stephen Browne, Brookefield Multiplex, Project Director: “Fusion completed their works at Reading on time and on budget. This has enabled Brookfield to install windows and make the building weather-tight much earlier in the programme than would normally be the case, allowing following trades to start work early. On Reading this will help provide greater certainty in meeting handover dates. But on future projects it opens up the possibility of reducing programme time overall, saving on prelims, reducing weather risk and improving the attractiveness of Brookfield’s overall offer to Clients.”

Mike Fairey, Director Fusion added; “This was our first project with the Brookfield team and I am pleased to see that all went according to programme which bodes well for the future. It was also great to hear that UPP were also impressed with our performance both on site and during design”

Hawthorn Student Village

Client: Cordil Construction Location: Saleen, Castlebar, Co. Mayo.
hawthorn-student-village
Project Size:
7,683m²
Build Time:
22 weeks approx.

Info

This accommodation was developed for students attending the Galway Mayo Institute of Technology (GMIT). The apartments, housing almost 300 students, are within their own campus at Saleen and encompass a central courtyard and landscaped private gardens.

Thomond Student Village

Client: John Fleming Construction Location: Limerick, Ireland
thomond
Project Size:
9,000m²
Build Time:
17 weeks

Info

Fusion has constructed the purpose-built Thomond Student Village for Limerick Institute of Technology. Thomond comprises 115 three bedroom apartments and is recognised for its exceptional design and facilities throughout Ireland.

St. Georges

Client: Willmott Dixon Location: South London
st-george-uk
Contractor / Developer:
Willmott Dixon
Project Size:
10,000m², 350 bedrooms
Build Time:
18 weeks

Info

Fusion have been involved in several phases of work at St. Georges in Tooting, South London. The first phase involved a 5 storey student accommodation block with 300 bedrooms and a total floor area of 10,000m². Subsequent phases involved the building of the UK’s largest key worker accommodation (600 beds). The final phase of works was the Horton Hall Student Blocks, which comprised of 150 bedrooms in 2 number 4-5 storey blocks (3,300m²)

Latest Case Study

Addlestone One – town centre regeneration

Addlestone
View Case Studies