Exceptional and Seamless Construction

CASE STUDY

Fusion’s ‘Product rather than Project’ thinking helped deliver the University of Sussex East Slopes Residences project – one of the single largest, successful offsite construction projects of its kind in the UK.

Balfour Beatty engaged Fusion at the concept stage of the University of Sussex East Slopes’ Residences project some three years before work started on-site, having previously worked together on a large student accommodation project for the University of Wales, Aberystwyth. Sequenced over five phases to deliver 29 blocks in 86 weeks and on a very tight and sloping site, the project required detailed planning for all parties. In order to optimise build speed and reduce site-based risks, Fusion invested in additional storage facilities to provide ‘just in time’ deliveries and worked with Balfour Beatty on their excellent decision to build a prototype unit on-site, helping identify issues which might not have been clear in the digital environment. The ground conditions for this site were extremely challenging. Working on a slope which at its steepest had a gradient of 1:6, the use of light steel meant less weight was being placed on the foundations – achieving success where many other build methods would have failed. Alsecco brick slip cladding was fixed to the external

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walls of our structure to create accommodation which would be extremely thermally efficient. U-values targets and low linear bridging were achieved and the completed structure was extremely airtight. The external wall build-up of each structure, which incorporated mineral wool and a sheathing board in front of the Fusion frame, also had a robust fire resistance – something which was further enhanced by the absence of a cavity. As always with steel, the structure will suffer very little movement, and therefore no need to repair any resulting cracks.

The Balfour Beatty team was keen to learn about Fusion system and as a result, supply chain integration workshop meetings were held regularly, with all trades involved. Balfour also appreciated the scale of this project meant it was a risk to supply chain partners, with many of them SMEs. The construction of Balfour’s prototype unit enabled the validation of the build principals. This was used during the build phase as a workshop facility and later as a marketing suite. Fusion’s design team held bi-weekly meetings with architects and Balfour’s design team to ensure every last detail was discussed and mutual decisions reached. Fusion manufactured its frames three months in advance of when they were needed – this maximised flexibility on the build and helped to minimise risk. Finally, with up to five blocks running concurrently, Fusion’s fast rate of build,

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pre-construction planning and absolute supply chain integration meant they delivered on-time and on-budget. “East Slopes has been a resounding success and for that outcome, we have to thank the fantastic interaction and collaboration of all trades working on the project,” said Geoff Grant, Project Director for Balfour Beatty UK Construction Services. “The ability to continuously improve as the build progressed through the numerous blocks benefitted by having Fusion’s light steel frame system at the core. And, while we were all on a learning curve together, it was the communication and mutual respect evident throughout the project teams which meant challenges could be overcome and improvements seamlessly introduced. Fusion’s system was the right choice for Sussex and their team had the right personnel for its delivery. I’m extraordinarily proud of what we’ve achieved so far and as Balfour Beatty continues to place investment in offsite methods of construction, I’m confident Fusion will be one our partners for many years to come.”

For more information visit: www.fusionbuild.com

Images:

01-02. Light steel frame proved to be a perfect solution on a very tight and sloping site.

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