Leicester, UK – [November 2025]
Offsite manufacturing specialist Drywall Pro-Cut has revealed how its partnership with Morgan Sindall on Project Medius helped deliver a complex, multi-use Leicester development – including two Accor hotels – in record time.
The £2.8 million drywall contract, completed over a 26-week programme, achieved exceptional efficiency gains through offsite production of British Gypsum components, saving 342 on-site working days and more than 2,700 labour hours.
Setting a New Benchmark for Time and Waste Reduction
Located on the former Great Central Railway site, Project Medius was designed to transform the area into a vibrant mixed-use development including two hotels and Grade-A offices. One of the hotels, a Novotel, marked a UK first – using pre-fabricated bathroom pods integrated with offsite-manufactured drywall components.
Drywall Pro-Cut’s team worked alongside Morgan Sindall from the early design stage, assessing site tolerances and opportunities for offsite production. Every component – from deflection heads to pod linings – was cut, labelled, and batched at the company’s Midlands manufacturing facility.
The result:
- 342 days saved through pre-manufactured drywall systems.
- 2,736 labour hours eliminated via precision-cut components.
- Improved on-site safety with zero manual cutting.
- BREEAM-aligned sustainability with reduced waste, transport, and dust.
Smart Manufacturing, Real Results
“This project exemplifies how offsite drywall can transform programme certainty and sustainability outcomes,” said a spokesperson for Drywall Pro-Cut.
“By shifting the most labour-intensive work into our controlled environment, Morgan Sindall achieved exceptional precision, reduced waste, and delivered ahead of schedule.”
The offsite production model also enabled full compliance with the Building Safety Act and Golden Thread documentation standards. Each component carried batch traceability, allowing total transparency from design through to installation.
Delivering for the Future of Construction
Drywall Pro-Cut’s success on Project Medius showcases the growing role of offsite drywall manufacturing in the UK’s drive toward faster, safer, and greener construction.
The company’s integration of British Gypsum systems and ISO 9001-certified processes provides contractors with measurable cost and sustainability benefits — particularly on high-density, fast-track builds like hotels and student accommodation.
“Our partnership with Morgan Sindall and British Gypsum demonstrates what’s possible when design, manufacturing, and installation come together in a unified workflow,” added the spokesperson. “We’re proud to be helping the industry redefine efficiency.”
Project at a Glance
| Component | Quantity | Labour Hours Saved | Labour Days Saved |
|---|---|---|---|
| Boards Cut to Size | 16,228 No. | 1,616 | 202 |
| Studs Cut to Size | 9,774 No. | 240 | 30 |
| Deflection Heads | 5,372 lm | 328 | 41 |
| Builders Work Openings | 280 No. | 168 | 21 |
| Pod Lining Sets | 252 No. | 384 | 48 |
| Total | – | 2,736 Hours | 342 Days |
About Drywall Pro-Cut
Drywall Pro-Cut is a UK leader in offsite drywall manufacturing, supplying pre-cut deflection heads, builders work openings, door sets, and ceiling components for major contractors nationwide.
Operating under ISO 9001 quality standards, the company works with British Gypsum and Siniat systems to deliver fire-rated, acoustic, and BREEAM-compliant solutions.
With clients including Morgan Sindall, BAM, and Mac Group, Drywall Pro-Cut helps main contractors achieve faster programmes, lower costs, and higher compliance standards through precision-engineered offsite production.
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Drywall Pro-Cut
No.7 Villiers Court, Meriden Business Park, Warwickshire CV5 9RN.
Email: enquiries@drywallpro-cut.co.uk
Phone: 01827 213201
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