In-house Design

Design is at the heart of the Fusion solution.  As such, Fusion continues to invest in its own in-house design resources comprising Engineers, Pre-construction Architectural Technicians and CAD Framers. The team are based at our main manufacturing facility in Northampton and satellite offices in Cork, Ireland and Zabrze, Poland.

Each office works in collaboration with the others, using the same intelligent, state of the art software solutions.


More than LGS Framing

In addition to expertise in LGS Framing, Fusion is able to offer advice and support on related topics such as fire, thermal and acoustics, based on experience gained on many thousands of dwellings, plus extensive R&D.


Hot Rolled Steel

Fusion has an unrivalled knowledge in integrating Hot Rolled Steel into our Light Gauge solutions to cater for items such as non-stacking load-paths, stairs, balcony and glazing support.  [picture of HRS detail]. Our in-house structural engineers provide us with the expertise needed to ensure our clients can rely on a single source of supply and responsibility for any HRS being integrated into the Fusion superstructure.


Early Design Support

At Fusion we understand that a successful LGS project requires early Design input and Fusion is committed to making the necessary resources available as early as possible. This early inclusion ensures our clients optimise the full benefits of a Fusion superstructure whilst creating the design integration to maximise supply chain cost benefits. [picture of erection team on-site at the Holywell School Project]

Concept Development

As far as Fusion is concerned, it is never too early to be involved in the Design process and we will be happy to provide advice on the potential suitability of your project for a solution based on LGS. This conceptual approach to design has proven a great success within Education, Student Accommodation, Care Home and Residential environments.



Factory Location

Fusion operates from an 80,000 sq ft factory in Northampton, in the East Midlands of the UK.  The factory is within 2 hours drive of well over 50% of the UK’s population.



Fusion rolls all its wall stud and floor joist components from LGS coils using CAD/CAM technology.  All components are uniquely numbered and notched, punched and cut to an accuracy of of +/- 0.5mm.



Pre-insulated Panel

External walls are pre-insulated in Fusion’s patented EPS moulding machine.  This unique process integrates structure, insulation and cladding support, in a single factory process.  The plant has a capacity of 3,000m2 / week on a single shift.


Adding Value With Off-Site Construction

Fusion’s business model is based on adding value via Design and Manufacturing.  The benefits of off-site construction are numerous but in the context of construction, Design For Manufacture and Assembly (DFMA) is best described as ‘adding value by improving quality through the application of efficiency’.

Seeking to find the most efficient way of delivering a project inevitably reduces the resources required (whether this is measured in cost, time, carbon, waste or labour) while increasing positive aspects such as health & safety, quality and certainty.

The common form of DFMA is the application of factory conditions to construction projects. This is critical for many reasons including;

  • Health & Safety – factory conditions are 80% safer than site conditions.
  • Cost – site labour is circa 2.2 times more expensive than factory based labour
  • Productivity – factory productivity reaches in excess of 80% compared with 40% for a typical site.
  • Sustainability – waste is reduced to 2% – 3 % in the Fusion factory.





The finished product remains the singularly most important thing we do. Regardless of excellence in design, manufacture and assembly, quite simply, if a structure is erected badly then all manner of problems appear. This is why Fusion retains in-house control of our structures throughout the project and takes responsibility for the end to end process – Design Manufacture Build.


The start of the Fusion build process. All vehicles are loaded in sequence to mirror the build programme. All packs are individually marked showing their weights to facilitate the onsite lifting process.



Fusion works with our clients to establish the crane/lifting plan on a project specific basis. The lightweight nature of the Fusion solution is clearly reflected in the small size of crane needed to lift our products. Which is not only ideal on cost but also very beneficial in projects where space is at a premium. Fusion has its own in house Appointed Person/s and Lifting Supervisors. We are always happy to plan for the taking on of the ‘lifting in’ of concrete or steel stairs or Pods.



We are very proud of our erecting teams, all of whom have had many years’ experience working on Fusion projects. Each ‘gang’ contains a supervisor, and where necessary, a ‘slinger banksman’ and or lifting supervisor.

We continue to invest in bespoke training for our ‘gangs’ focused on the erection of the Fusion system including; Health & Safety, the correct methodology, fixings and numerous processes needed to complete a successful build complying with our structural regulations.


Sign Off

As part of our SCI structural accreditation Fusion will provide ‘sign off’ on our structures by a chartered structural engineer. As-built drawings and engineering calculations are also provided post-erection.



Latest Case Study

Chorley Street, Bolton

Chorley Street
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