HMP Northumberland - Offsite Manufacturing for Onsite Efficiency

Offsite Manufacturing Driving the Expansion of HMP Lancaster Farms

Work is progressing rapidly on the Category C HMP Northumberland expansion in Market Harborough, where PCE Ltd has been selected by Kier to deliver the superstructure and façade for four new two-storey houseblocks. The scheme will add 240 prison places to the existing facility as part of the Ministry of Justice’s ongoing prison capacity programme.

Building on a Trusted Track Record

PCE and Kier bring a history of successful collaboration on custodial projects across the UK. Drawing on experience from HMP Five Wells, HMP Fosse Way, HMP Millsike and other facilities, the HMP Northumberland expansion again leverages PCE’s HybriDfMA Secure Prison System—a Platform-DfMA solution based on an optimised Kit-of-Parts tailored to project-specific requirements.

Precision Offsite Production

Across six specialist factories within PCE’s European supply network, around 2,200 engineered components are being manufactured. This kit comprises:

• External solid walls & brick-faced sandwich panels
• Precast columns, beams and internal walls (loadbearing & non-loadbearing)
• Hollowcore planks, stairs, landings and insitu toppings
• Structural steel, Deltabeams®, parapets, upstands and plinths

Quality at Every Stage

Each unit is designed for robustness and longevity, with concrete strengths from C35/45 to C60/75 and a 100-year design life. Production in controlled factory settings ensures consistent Type C finishes, while first-cast benchmarks, agreed by PCE, Kier and the MoJ, establish the reference standard for the entire programme. PCE quality specialists are present in factories throughout manufacture to maintain uncompromising standards.

To embed security and M&E provisions from the outset, more than 55,000 free-issue items—including cell doors, windows and conduits—are installed during casting.

Digital Oversight & Transparent Delivery

PCE’s Ynomia platform generates a 3D digital twin, assigning each component a Bluetooth tracker for full lifecycle visibility. Real-time status updates enable just-in-time logistics, accurate forecasting and an integrated record of QA data, underpinning Golden Thread compliance.

Lowering Carbon Impact

Insights from the Decarbonising Precast Concrete initiative—developed with the MoJ and industry partners—have delivered a 12% reduction in embodied carbon compared with HMP Fosse Way, equivalent to 753 kg CO2e per prisoner place, while maintaining full structural integrity.

Setting a Modern Benchmark

The HMP Northumberland expansion reflects how advanced offsite manufacturing, digital precision and carbon-conscious design can deliver secure, efficient and future-ready prison infrastructure. PCE’s HybriDfMA approach continues to shape a new standard for modern custodial construction.

Images taken from different prison projects