Offsite Efficiencies - Manufacturing Brent Cross Plot 14
PCE Ltd has been appointed by main contractor Galliford Try as the superstructure and façade specialist for Brent Cross Town Plot 14. Using its HybriDfMA build system, hyTower®, PCE will assemble nearly 4,500 offsite manufactured components, realising the vision of architects Allies and Morrison and Whittam Cox with safety, quality, speed, and value. Plot 14 will feature three high-rise residential blocks up to 12 storeys, providing 286 Build to Rent apartments, as part of the larger £8bn Brent Cross Town development by Related Argent and Barnet Council.
Kit-of-Parts
PCE’s systemised build solutions involve the offsite manufacture of pre-engineered components that come together to form a ‘kit-of-parts’. Through extensive material expertise and common connection principles, PCE’s build systems enable a hybrid blend of different structural materials. It means each system can be uniquely configured to suit each project’s specific requirements, ensuring the right product for the right solution. This means we can deliver structural solutions that combine proven optimisation of a systemised approach, with bespoke architectural aspirations.
For Plot 14, the kit of parts combines 4,500 steel and precast concrete structural components:
- Precast concrete twinwall
- Sandwich panel with integrated façade
- Stairs and landings
- Steel columns
- Steel transfer beams
- Reinforced steel composite beams
- Hollowcore components
In line with its flexible supply chain model, PCE will engage 5 offsite specialist manufacturers from across the UK and Europe to manufacture its standardised components.
Quality Assurance
- 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 and Integration
PCE’s offsite manufacturing approach also integrates required sub-assemblies during production, such as windows, MVHR ducts, balconies, and façades (using 4 different colours comprised of both brick and reconstructed stone).
Integrating these elements offsite ensures components are ready for immediate assembly upon arrival.
Smart Digital Systems
PCE leverages advanced digital systems to manage and track the entire process, including manufacturing and just-in-time logistics:
- Digital Twin Technology: Ynomia’s automated digital twin technology visualises real-time project progress through interactive 3D models.
- Performance Tracking: Digital tracking captures performance and quality metrics, guiding manufacturing strategies and ensuring timely project delivery.
Through these methods, PCE ensures the highest standards of quality and efficiency, underpinned by smart digital strategies that aid in project coordination and compliance with The Golden Thread.
Just-in-Time Delivery
To ensure efficiency, PCE follows a just-in-time delivery system where components arrive on-site only when needed. This includes casting certain components within two weeks of their installation date, whilst tracking all components real time as they progress from design, through manufacture and logistics, to assembly and handover.
