Medius – Offsite Drywall Manufacturing for a 26-Week Hotel Build

How Drywall Pro-Cut Helped Morgan Sindall Deliver a Complex Development on Time and on Budget

Project Overview

Client / Main Contractor: Morgan Sindall
Location: Leicester, UK
Project Type: New Build – Two Accor Hotels (Novotel & Aparthotel)
Product Specification: British Gypsum plasterboard systems
Features: Bathroom pods, M/F ceilings, fire-rated partitions
Drywall Contract Value: £2.8 million
Programme Duration: 26 weeks

The Challenge

Morgan Sindall’s Project Medius aimed to transform the former Great Central Railway site into a vibrant mixed-use development – including two hotels and Grade-A office space.

The challenge:

Deliver a two-hotel fit-out with integrated bathroom pods on a 26-week timeline.
Maintain consistent fire and acoustic performance across multiple buildings.
Reduce on-site waste, manual cutting, and installation risks in a constrained city-centre location.

The project demanded speed, precision, and sustainability, with zero tolerance for rework or waste.

The Drywall Pro-Cut Solution

Drywall Pro-Cut supplied a full range of offsite manufactured drywall components, designed, cut, and delivered to Morgan Sindall’s exact specifications.

Products Supplied

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

Measurable Outcomes

342 working days saved, accelerating completion by over 6 weeks.
2,736 labour hours eliminated, allowing Morgan Sindall to reallocate resources.
Zero on-site cutting, improving health and safety outcomes.
Improved sustainability, with reduced skip use and transport emissions.
Fire-rated assurance, using British Gypsum specification systems across all zones.

The Process

Drywall Pro-Cut’s engineering team conducted a comprehensive site survey with Morgan Sindall to assess layout tolerances, soffit heights, and partition locations.

Measurements were digitised, then processed at our offsite manufacturing facility, where each component was:

CNC-cut to exact dimensions.
Labelled and batched by floor for sequential installation.
Shipped with marked-up drawings to guide on-site teams.

This approach ensured immediate readiness on arrival – no on-site cutting, no confusion, no rework.

Sustainability and Compliance

BREEAM-aligned efficiency: Reduced on-site waste and skip usage by up to 60%.
ISO 9001-certified quality management: Ensuring every component met performance and traceability requirements.
CCPI and Golden Thread compliance: Full documentation for post-completion audit and asset traceability.
Reduced embodied carbon: Fewer deliveries, shorter on-site operations, and less dust and waste.

Why Contractors Choose Drywall Pro-Cut

Guaranteed Programme Certainty: Offsite batching and sequencing keeps your project on schedule.
Compliance Confidence: All products meet UK Building Safety Act, fire, and acoustic standards.
Sustainable Delivery: Quantified waste and carbon savings on every project.
Design-to-Delivery Partnership: From CAD drawings to installation-ready components.
National Scale: Proven capability on complex multi-site and high-volume projects.

High-Intent Buyer FAQs

How much time can offsite drywall manufacturing save on hotel projects?

For Medius, offsite drywall production saved 342 days and reduced overall project time by nearly six weeks, helping the main contractor meet critical handover dates.

Can offsite drywall components be used with bathroom pods and modular systems?

Yes. Our pre-cut boards and studs were used directly in Accor Novotel bathroom pods, demonstrating full compatibility with modular fit-outs.

Are Drywall Pro-Cut's products compliant with the Building Safety Act?

Absolutely. Each item includes batch traceability, CCPI compliance, and Golden Thread documentation for full post-occupancy accountability.

How does offsite drywall reduce costs for contractors?

By cutting boards and studs at source, we eliminate rework, reduce waste disposal costs, and lower on-site labour – typically saving 10-15% of total fit-out costs.

How can I request a quotation for an offsite drywall project?

Send your architectural drawings or take-offs to enquiries@drywallpro-cut.co.uk. You’ll receive a detailed quotation and optimisation proposal within 48 hours.

Building Smarter with Offsite Drywall

The Medius project demonstrates how offsite drywall manufacturing delivers measurable efficiency, sustainability, and compliance on complex, fast-track builds.

Partner with Drywall Pro-Cut to transform your next commercial, hospitality, or mixed-use development.

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

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