Brent Cross Plot 1: Pioneering Hybrid Construction with Innovation and Sustainability

Part of the £8bn Brent Cross Town development, 3 Copper Square is a 14-storey office building with 239,000ft² of office space and flexible retail areas. Key features include a double-height reception, easy access to the station, and a penthouse with panoramic views of North and Central London. PCE, in partnership with Main Contractor BAM Construction, is delivering the project with design support from Curtins, bringing ShedKM’s architectural vision and Heyne Tillett Steel’s engineering design to life.

Innovative Hybrid Structure

This project features a pioneering hybrid structure combining Cross Laminated Timber (CLT), precast concrete, and recycled steel. Utilising PCE’s HybriDfMA Frame build system, the ‘kit of parts’ approach uses over 4,800 offsite-engineered components, integrating standardised beams, columns, walls, and slabs, installed by 24 multiskilled operatives . This mix of materials and the incorporation of engineered timber reduces embodied carbon, making the whole lifecycle carbon of the building 29% better than the GLA’s benchmark target (excluding tenant fitout), and nearly 10% better than LETI 2030 targets.

3 Copper Square will be one of the tallest in Europe to combine precast concrete with cross-laminated timber, whilst marking PCE’s inaugural use of engineered timber, reinforcing its commitment to sustainable hybrid construction.

Precision in Design and Assembly

A key factor in the project’s success lies in material interfaces. Design expertise within hybrid materials ensures seamless integration of CLT floors with precast beams, composite steel beams, and steel angles. This careful calculation and ‘smart connectivity’ across components achieves precision assembly, driving efficiency in both manufacturing and onsite construction.

Offsite DfMA Delivery

The offsite Design for Manufacture and Assembly (DfMA) approach plays a crucial role in minimising site disruption. By completing a large portion of the work offsite, PCE reduces site deliveries and onsite personnel by up to 80% and cuts waste by up to 90%. This approach enhances sustainability, ensures high-quality components, and supports a just-in-time strategy for greater onsite efficiency.

Strategic Logistical Planning

PCE’s meticulous design and planning also allow for efficient construction just inches away from the active Brent Cross West train station and railway line. With predictable tolerances and precise assembly, the project progresses without disrupting nearby infrastructure.

Brent Cross Town 3 Copper Square is a prime example of PCE’s innovative hybrid construction, showcasing sustainable materials, offsite manufacturing, and precision engineering.

As part of its structural solution, PCE provide: