Drylining Prefabrication

The One Hit Wall System utilises early design coordination, standardisation, and off-site manufacturing to enable approximately 90% prefabrication of drylining elements before they arrive on site. This includes components such as baffle boxes, head tracks, letter boxes, pattresses, door heads, back boxes, and conduits. All wall boards and studs are site measured and delivered pre-cut, allowing for faster installation and significantly improved consistency, quality, and accuracy throughout the project. By reducing reliance on individual workmanship on site, the system helps ensure compliance with British Gypsum (BG) specifications while providing a cleaner and more coordinated handover to MEP contractors. The approach also minimises rework, design alterations, and material waste, creating a more efficient construction process.

A major advantage of the system is its contribution to sustainable construction practices. The extensive use of prefabrication reduces material waste, improves manufacturing efficiency, and lowers carbon emissions compared with traditional on-site installation methods. Recycled timber is used for pattresses, and any offcuts generated during manufacturing or installation are collected and returned through the British Gypsum recycling programme, where more than 97% of the waste material is recycled. By standardising drylining components across the project, the system achieves a consistent and compliant installation while significantly reducing waste generation and the environmental impact associated with site-based cutting and material handling.

The One Hit Wall System delivers benefits that extend beyond sustainability to include improvements in safety, quality, and programme certainty. Reduced on-site cutting lowers dust generation, minimises the use of power tools, and creates a healthier working environment for operatives. The prefabricated approach also improves installation accuracy, reduces defects, and ensures consistent quality standards across all areas of the project. By shortening installation periods and reducing the overall project duration, the system helps minimise disruption to the surrounding area while supporting net-zero ambitions through reduced carbon emissions and lower volumes of waste sent to landfill. Overall, the approach demonstrates how modern methods of construction can successfully combine sustainability, safety, efficiency, and quality in large-scale building projects.