HMP Fosse Way Houseblock 8 - Offsite Manufacture

HMP Fosse Way, is set to expand its capacity by 250 prison places through the construction of a new houseblock.

Following PCE’s contribution to the successful delivery of the category C resettlement prison in 2021, the company will once again employ its HybriDfMA Secure Prison system for this project. Lendlease, the main contractor, has appointed PCE to work with them to expand the prisons capacity. 

Secure Prison, a hybrid platform-DfMA (Design for Manufacture and Assembly) build system, has proven its effectiveness as the blueprint for scalable solution across the New Prison Programme. Having been utilised in projects such as HMP Five Wells (2020), HMP Millsike (2023), and HMP Fosse Way (2021), it has since been selected for the expansion of HMP Elmley, and HMP Bullingdon, and once again at HMP Fosse Way.

Using its unique supply chain model, PCE enjoy the flexibility to hand pick the most appropriate suppliers from across the UK and Europe, ensuring the right product is used for the right solution. The T60 and supporting ancillary units will see over 1,700 PCE components manufactured offsite by 5 different specialists across a 26-week period. In addition, nearly 8,000 free issue castings are integrated throughout the offsite solution.

Offsite Quality Control

Through Modern Methods of Construction (MMC), PCE ensure the highest quality standards across manufacture. Working closely with its supply chain, steps are taken to ensure quality remains consistent. Standards are agreed across the project team and then maintained through diligent offsite quality control; this includes PCE quality controllers overseeing and supporting production across the supply chain.

Standardised Repeatability

Through its platform-DfMA methodology, PCE’s Secure Prison system’s ‘kit-of-parts’ is optimised for quality, efficiency, and repeatability. Bespoke moulds ensure predictable precision, meaning components are not only more sustainable, using 12% lower embodied carbon concrete mixes, they maintain a consistent high-quality finish throughout. This not only looks good and performs well, it enables direct direction, negating the need for excess materials such as plasterboard.

The repeatable ‘kit of parts’ include precast floor/ceiling units, sandwich panels with integrated windows, corridor walls with cast-in cell door frames, internal walls, columns, stairs, landings, and parapets. Components have constituent parts integrated throughout production, including structural ties, builders-work openings, and encased M&E sub-assemblies.

Digital Delivery

Smart digital systems enable PCE to manufacture at scale. It allows efficient coordination of large-scale operations, capturing performance and quality metrics along the way. Use of Ynomia’s advanced automated digital twin technology visualises real-time project progress, projected through interactive 3D models. The insights gained through PCE’s digital approach influences manufacturing strategies, enabling calculated just-in-time project delivery.

Road to Rehabilitation

Whilst manufacturing sees components coming in from different factories across the UK, a number are coming from within HMP Fosse Way itself. Through PCE’s workshop programme, prisoners nearing release have been upskilled and trained to work in a manufacturing environment. This has enabled them to manufacture precast columns and riser upstands, both of which are being used for the assembly of the T60. The initiative, aimed at promoting rehabilitation and reducing reoffending, is being led by PCE in collaboration with the MoJ and Serco.