Equipoint – Office-to-Residential Conversion

Offsite Drywall Manufacturing for Urban Redevelopment Projects

Project Overview

Client / Main Contractor: Mac Group
Location: Birmingham, UK
Project Type: 10-storey office-to-residential conversion with new penthouse level
Product specification:
– British Gypsum systems
– Twin walls with Resi Bar
– 70mm stud with two layers of SoundBloc
– M/F ceilings
Drywall Contract Value: £2 million
Programme Duration: 40 weeks

The Challenge

The Equipoint redevelopment transformed a disused commercial office tower into 247 high-quality residential apartments within just 40 weeks.

Mac Group required a fast, accurate, and low-waste drywall installation process to meet the compressed programme schedule.

The challenge involved:

Precision fitting across 10 storeys and a new rooftop penthouse.
Reducing labour and on-site congestion in a high-rise environment.
Achieving compliance and acoustic performance in line with residential standards.

Traditional drywall cutting and assembly on site would have slowed installation and generated excessive waste and dust – both unacceptable in a project of this scale and specification.

The Drywall Pro-Cut Solution

Drywall Pro-Cut provided a fully managed offsite drywall manufacturing service, from site survey to delivery.

After assessing the existing soffit and floor levels, our team took precise measurements and produced all components at our Midlands manufacturing facility.

Components Supplied

Component	Quantity	Labour Hours Saved	Labour Days Saved
Boards Cut to Size	8,680 No. (28,423 m²)	864	108
Studs Cut to Height	6,340 No.	176	22
Deflection Heads	3,328 lm	208	26
Door Sets	280 No.	24	3
Builders Work Openings	750 No.	464	58
Total Savings	–	1,736 Hours	217 Days

Each component was labelled, batched, and accompanied by marked-up drawings, ensuring site teams could identify and install every piece immediately upon delivery.

Results & Measurable Outcomes

217 on-site labour days saved: freeing resources for parallel works.
1,736 labour hours eliminated, delivering substantial programme acceleration.
Significant waste reduction, reducing skip hire, transport, and disposal costs.
Improved acoustic and fire-rated performance using British Gypsum systems.
Sequenced deliveries, ensuring installation stayed ahead of schedule.

This approach ensured programme certainty, reduced project overheads, and supported BREEAM-aligned sustainability goals through offsite efficiency.

Sustainability and Compliance

All materials were produced under ISO 9001-certified manufacturing conditions, guaranteeing quality, safety, and compliance with the Building Safety Act and Golden Thread requirements.

Through offsite cutting and batching, Drywall Pro-Cut helped Mac Group:

Prevent excessive plasterboard waste.
Improve site safety with reduced manual cutting.
Support BREEAM Wst 01 and Mat 05 credits.
Enhance traceability for fire-rated systems and acoustic partitioning.

Why Developers Choose Drywall Pro-Cut

Guaranteed Programme Efficiency: Sequenced, ready-to-install deliveries that remove on-site bottlenecks.
Reduced Costs: Less waste, fewer skips, and lower labour requirements.
Assured Compliance: Fire-rated, acoustic, and sustainability-verified systems.
Precision Engineering: CNC cutting for millimetre-perfect installation.
Nationwide Coverage: Delivering across all major UK city regeneration zones.

FAQs

How much labour time can offsite drywall save on conversion projects?

On Equipoint, Drywall Pro-Cut saved 217 working days through precision cutting and batching. Most large-scale conversions see 30-50% faster installation than traditional methods.

Are offsite drywall systems suitable for mixed-use or high-rise conversions?

Yes. Our solutions are designed for multi-storey and complex layouts, including office-to-residential and hotel conversions, where vertical logistics are critical.

How does offsite drywall support compliance with the Building Safety Act?

Every product we manufacture includes traceable batch labelling, digital records, and CCPI certification, ensuring full transparency under the Golden Thread framework.

Can Drywall Pro-Cut supply fire-rated and acoustic systems?

Absolutely. We work exclusively with British Gypsum systems, manufacturing fire- and sound-rated components tailored to project requirements.

How can I request an offsite drywall quote for a conversion project?

Email your plans to enquiries@drywallpro-cut.co.uk. You’ll receive a free technical review and quotation within 48 hours, including material optimisation recommendations.

Transforming How the UK Builds

Drywall Pro-Cut is redefining how large-scale conversions are delivered.

Through offsite precision, sustainability, and compliance, we help contractors and developers meet timelines, budgets, and environmental targets.

Call: 01827 213201 | Email: enquiries@drywallpro-cut.co.uk

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