FAH Coventry University

Offsite Drywall Manufacturing for Large-Scale Educational Redevelopment

The Challenge

The Faculty of Arts and Humanities (FAH) redevelopment at Coventry University required the repurposing of two existing buildings and the construction of a new academic block.

McLaughlin & Harvey needed a partner that could:

• Reduce on-site labour and dust exposure within an active university campus.
• Deliver consistent quality across a multi-phase, high-specification fit-out.
• Support tight programme schedules while maintaining BREEAM-aligned sustainability targets.

Traditional drywall fabrication on site would have slowed progress, created waste, and increased health and safety risks.

The Drywall Pro-Cut Solution

Working in partnership with Taylor Hart Ltd, Drywall Pro-Cut supplied a complete package of offsite manufactured drywall components, including:

• 3,491 linear metres of 72mm deep-track deflection heads with dual-layer coreboard.
• 570 builders work openings, pre-sized to exact M&E coordination drawings.
• 248 door sets, pre-cut and drilled for rapid installation.

Each component was produced in our controlled facility, labelled, and batched for delivery by floor and zone – reducing on-site cutting and accelerating installation.

Measurable Results

Key Outcomes

• 76 on-site labour days saved, freeing up contractor resources.
• Improved health and safety through reduced manual handling and cutting.
• Streamlined programme – the drywall phase completed in just 33 weeks.
• Waste minimised through precision manufacturing and no on-site offcuts.
• Sustainable compliance supporting BREEAM and ESG targets.

Sustainability and Compliance

All components were manufactured under ISO 9001:2015 quality management and aligned with:

• BREEAM Wst 01 waste reduction and Mat 05 responsible sourcing credits.
• Golden Thread and CCPI traceability standards.
• Building Safety Act compliance for full product documentation and accountability.

This approach not only reduced the environmental footprint but also improved installation accuracy and programme certainty across the project.

Why Contractors Choose Drywall Pro-Cut

• Programme certainty: Phased, just-in-time deliveries minimise on-site congestion.
• Safety and compliance: No cutting, dust, or additional handling required.
• Sustainability built-in: Measurable reductions in waste and embodied carbon.
• Fire and acoustic compliance: Pre-certified with British Gypsum systems.
• Nationwide delivery: Scalable support for multi-site contractors.

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