Phoenix Group – Sheffield Hallam University

Offsite Fire-Rated Deflection Heads for Education Sector Efficiency.

The Challenge

As part of a major expansion of Sheffield Hallam University, BAM required additional teaching spaces to be completed under tight deadlines.

The project presented three key challenges:

1. Programme Pressure

Meeting strict completion deadlines within an active university campus.

2. Health & Safety Compliance

Minimising on-site dust and manual cutting.

3. Sustainability Targets

Reducing plasterboard waste and improving environmental performance.

Traditional on-site fabrication of fire-rated deflection heads would have caused delays, created dust hazards, and increased waste disposal costs.

The Drywall Pro-Cut Solution

Drywall Pro-Cut supplied pre-fabricated fire-rated deflection heads, manufactured offsite using two layers of 25mm British Gypsum Glasroc on an extra-deep track system.

Each component was:

• Cut to exact specification from contractor drawings.
• Labelled and batched by zone for phased delivery.
• Delivered ready to install, eliminating on-site cutting and rework.

This offsite manufacturing approach ensured seamless coordination with BAM’s installation teams and kept the university environment clean and safe during construction.

The Drywall Pro-Cut Solution

Results at a Glance

• 199 labour hours saved: equivalent to 25 on-site working days.
• 1.4 tonnes of GRG waste prevented: reducing transport and disposal costs.
• Zero on-site cutting: improving safety and air quality.
• Guaranteed compliance: aligned with CCPI, Golden Thread, and Building Safety Act standards.

Sustainability and Compliance

By manufacturing and assembling offsite, Drywall Pro-Cut eliminated the need for on-site plasterboard cutting and achieved:

• Reduced embodied carbon emissions through less transport and skip usage.
• Compliance with BREEAM and LEED frameworks.
• Traceable quality assurance under ISO 9001-certified processes.

This project set a new benchmark in how offsite drywall manufacturing supports education-sector builds – delivering speed, precision, and sustainability.

Why Education Contractors Choose Drywall Pro-Cut

• Faster project delivery through just-in-time manufacturing and sequenced logistics.
• Consistent fire-rated performance across all drywall elements.
• Reduced on-site labour risk and improved H&S compliance.
• Documented traceability to satisfy client and regulatory requirements.
• Significant sustainability savings for BREEAM and ESG reporting.

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