Off-site Manufacturing

Embracing off-site construction allows us to streamline our processes, reduce waste, and deliver homes of exceptional quality more efficiently and cost-effectively, ultimately benefitting both our clients and the environment.

Fusion is an off-site manufacturer offering complete solutions in light gauge steel frame panellised superstructures, covering design, engineering, manufacture, and installation. Based in Northampton at their high-grade manufacturing facility, Fusion’s mission is to improve the entire building process by implementing more efficient supply chain solutions that integrate high-quality off-site manufacturing with on site processes.

Fusion’s core product, FUSIONX™, is a fully tested non-combustible walling solution developed in response to building regulation changes. Approved by the NHBC and registered under NHBC Accepts, FUSIONX™ holds LABC Warranty and is BOPAS accredited. The load-bearing external walling system is also SCI and NHBC certified up to 10 storeys and can form part of a structure up to 14 storeys.

In 2023, we updated Fusion’s brand, ensuring it was more closely aligned with our corporate brand family investing in new branded clothing, literature, and factory signage, which has helped reinforce the company’s values.

In April 2023, Fusion launched TRAX, a highly economical, customisable, non-load-bearing infill walling system designed for concrete or steel superstructures, capable of accommodating a wide range of cladding systems. TRAX offers a high level of thermal and acoustic insulation, enhancing overall building performance. Using advanced CAD/CAM technology for precision and consistency, its use can vastly reduce the risk of errors and delays in construction.

Kew Bridge Rise, delivered in partnership with L&Q, is an emerging project where we are excited to see the benefits of Fusion’s TRAX product in use. 

Fusion is manufacturing and installing the infill walling system as part of the redevelopment of the former Citroën garage in Brentford. 

The company will fabricate 13,720m² of TRAX for the project, forming the steel frame system infill across five buildings of up to 18 storeys. The development will have a concrete frame structure, and Fusion will create the window apertures, install roofing membrane, external insulation, and wall tie channels, providing a complete solution for the project.

Construction of the steel frame system has already begun on site, with the development expected to complete in 2026.

Many Hill developments incorporate standardised bathroom pods and prefabricated utility cupboards (PUCs) designed by our manufacturing partner and modular homes specialist, Volumetric Modular Ltd (VML).

VML is a specialist manufacturer of award-winning modular solutions. Utilising off-site methods and DfMA principles, its range of modular homes, bathroom and en-suite pods, and mechanical electrical and plumbing (MEP) pods are designed to meet the growing demand for high-quality, sustainable volumetric modular technology.

Many Hill developments incorporate standardised bathroom pods and prefabricated utility cupboards (PUCs) designed by our manufacturing partner and modular homes specialist, Volumetric Modular Ltd (VML). 

VML is a specialist manufacturer of award-winning modular solutions. Utilising off-site methods and DfMA principles, its range of modular homes, bathroom and en-suite pods, and mechanical electrical and plumbing (MEP) pods are designed to meet the growing demand for high-quality, sustainable volumetric modular technology.

Since acquiring a 50% stake in VML in 2020, we have worked together to enhance our designs and update specifications to improve equipment functionality, aesthetic appeal, and overall quality. This collaborative effort ensures that our modular homes meet the highest standards. 

We have proactively developed our supply chains to enhance efficiency, drive value, and ultimately optimise production, so we can deliver high-quality modular homes in a timely and cost-effective manner, to help meet the evolving needs of our communities.

VML’s pods are built in its off-site factory to specification and design requirements. This ensures greater longevity due to the materials used, a quicker build time, reduced waste, and improved quality.

Kew Bridge Rise, in Brentford, is one of the first of our developments to use VML’s modular bathroom pods and PUCs within every apartment across Phase B.

VML was selected to design and manufacture bathroom and MEP pods for the Kew Bridge Rise development with the first units delivered to site in March 2023. 

The precision-engineered pods arrive fully assembled, tested, and certified, making them ideal for projects where speed and ease of installation are vital to achieving strict building programmes.

VML’s bathroom and MEP pods use 3D printing technology and augmented and virtual reality prototyping to ensure accuracy and quality. The light steel framing requires significantly less room than traditional partition walls and has been designed for optimal spatial efficiency.

Designed with sustainability in mind, the pods are eco-friendly and cost-efficient. Low-energy lighting reduces fuel consumption, while controlled flow showers and dual-flush cisterns mitigate water waste.