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.
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.