Commodity Construction - Offsite Repeatability For Added Value

Led by John Sisk & Sons for the Silvertown Partnership, which includes Lendlease, PCE have been appointed to deliver the structural frame for Silvertown Plot 6. Located meters from the City of London Airport, Plot 6 is the first development within the 50-acre Silvertown regeneration.

PCE’s Hybrid Frame systemised build solution is being used to deliver the structural frame, which consists of both concrete and steel. The structure will consist of three blocks, each 6 storeys tall, and will provide 5 storeys of modern, affordable housing above commercial spaces and parking.

Using Hybrid Frame, PCE’s systemised approach will bring together an offsite manufactured ‘kit of parts’ pre-engineered and predetermined for an efficient, fast structural solution with certainty of outcome.

 

Offsite Manufacturing for Silvertown Plot 6

By pre-engineering and manufacturing structural elements offsite, PCE significantly reduces project risks while enhancing quality, speed, and efficiency. Our key principle is using the right material for the right job, ensuring each component is optimised for performance, aesthetics, and sustainability.

For Silvertown Plot 6, our ‘kit of parts’ solution includes a mix of over 2,300 precast concrete and steel components, manufactured by 4 different offsite specialists from across the UK and Europe. This comprises 6m double-height precast concrete twin walls, internal walls, steel columns, steel transfer beams, steel composite beams, precast stairs and landings, and hollowcore flooring. Around 75-80% of Plot 6's kit of parts components are considered 'commodity products', which use the same methods and details across designs, connections, fabrications, and installation. 

In addtion, riser upstands were manufactured by prisoners at HMP Fosse Way as part of a rehabilitation scheme led by PCE with Serco's support. This program trains and upskills prisoners in manufacturing, producing components for public and private construction projects, including Plot 6. Its goal is to equip prisoners nearing release with new skills and a career pathway for successful reintegration into society, helping to reduce reoffending.

PCE's 'smart connectivity' and common connection principles ensure seamless integration of a hybrid of materials, allowing for bespoke solutions while maintaining the predictability and certainty associated with a systemised build solution.

 

Control Mechanisms

PCE employs Modern Methods of Construction (MMC) to ensure the highest quality standards and operational efficiency. Key aspects of our approach include:

Quality Standards:

  • Quality benchmarks are established by PCE, the client, and the supply chain.
  • Specialist offsite manufacturers from the UK and Europe produce components in controlled factory environments.
  • Manufacturing automation and robotics ensure consistent component quality.
  • PCE quality controllers oversee production across the supply chain.

Efficiency:

  • A just-in-time delivery system ensures components arrive on-site only when needed.
  • Twinwall and hollowcore components are cast within two weeks of their installation date.
  • Offsite integrations of sub-assemblies, such as stair balustrades, are pre-fitted for added value and quicker assembly

Smart Digital Systems:

  • Advanced automated digital twin technology from Ynomia visualises real-time project progress through 3D models.
  • Digital tracking captures performance and quality metrics, guiding manufacturing strategies and ensuring timely project delivery.
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