Drywall Pro-Cut
Innovation overview and development
An overview of the product
DRYWALL PRO-CUT
The future of drywall installation.
Drywall Pro-Cut makes essential drywall components such as deflection heads, builders work openings and door sets which are currently awaiting Patent Granted Status, in an off-site facility, to improve precision, quality and installation time on-site.
Produced by specialist laser guided machinery, the ready-to-fit parts are delivered to site and used in the construction of walls requiring crucial fire, acoustic and structural properties.
This method of off-site construction gives customers peace of mind that crucial components are made to specification every time, while driving significant cost and on-site waste savings.
How the new product was developed, including effective collaboration, knowledge transfer and partnership along the project team
This innovative way of thinking has been developed with input from leading specialists in the industry. Partnered with a leading Dry lining and fit out contractor in the Midlands it has been developed over the past 6 years with input from manufacturers, specifiers and installers, all with the same goal of improving efficiency, quality and peace of mind knowing crucial elements to maintain integrity are adhered.
Over this time we have taken many different approaches, firstly starting by placing handheld cutting machines on site using the Flextos XPM, to 6 years later having our own off-site facility producing components from all 3 of the UK’s leading Dry-wall manufacturers utilising the Flextos XPS machines complete with Dust control extraction providing 99% dust reduction.
How might this product have an influence on the specification
One of the main qualities of our products is the fact it is produced in a factory environment, complying 100% with all necessary construction details required to maintain the fire, acoustic and structural integrity of the partition in which they are used. With many different site operatives interpreting details differently, it can become common for these important components to be produced/installed with slight variances, becoming non-compliant. Here at Drywall Pro-cut we take this huge risk away, providing our clients with a greater peace of mind.
How the product improved productivity in the process and/or quality and performance of the interior system
Producing these labour intensive products off-site reduces the volume of site operatives required at the workface. This, in-turn, reduces the time required on site for installation. We have conducted studies which show that utilising Drywall Pro-Cut components can reduce programme time, or labour levels on site by 31%. Please see below link to our ‘race’ experiment where we pitted the installation of traditional and off-site components
There are multiple safety benefits to be gained from using Drywall Pro-Cut products. Our products reduce the need for cutting stations and associated trailing leads and dust production, circular saws, saws and Stanley knives both on and off site creating a safer environment and a tidier work place.
A major driver within the construction industry and for us at Drywall Pro-Cut is sustainability. Dry lining produces a high quantity of waste. By producing products off-site we have a greater control over waste levels, re-using off-cuts wherever possible. In doing so we reduce the overall carbon footprint of the dry lining trade. Less board, less deliveries, less removals (skips), less waste.