10,000 Bespoke Brackets For N2 Nova East

Faced with tight deadlines, limited labour and restricted space on-site, our customer, a leading M&E contractor, was up against a significant challenge; how to produce 10,000 bespoke service brackets without derailing their schedule. Fabricating this quantity of brackets on-site just wasn’t feasible, so they turned to Kernow Fixings for a solution.

The brackets were required for the landmark N2 Nova East project, a key part of the Nova masterplan in Victoria, Central London. Positioned adjacent to the Grade II listed Victoria Palace Theatre, this 18-storey structure provides over 160,000 sq ft of premium Cat A sustainable office space achieving a BREEAM ‘Outstanding’ rating and ‘WELL’ Gold certification.

What Did Kernow Supply?

A total of 10,128 independent M&E brackets were designed and fabricated by Kernow’s prefabrication team. These were made up of 17 different designs, with most assemblies consisting of a prefabricated bracket and separate extension studding. The studding was pre-assembled with an anchor fixing at one end and a connection fitting at the other to easily attach to the bracket. This solution allowed the brackets to suit the development’s unusually high ceilings, whilst remaining easy to transport and handle on site.

How Did Off-Site Fabrication Benefit The Project?

Producing this quantity of brackets on-site would have taken weeks, if not months, of labour time. Cutting thousands of channel lengths and studding, then assembling all the brackets into complete units ready for installation, would have been a huge undertaking. It would have required a dedicated fabrication area, secure storage, and compliance with hot works permits and other Health & Safety regulations.

Kernow’s Off-Site Fabrication service eliminated all of these potential issues. The brackets & studding assemblies were produced in our dedicated prefab facility, using a streamlined production line to ensure speed, precision and consistency. Bulk cutting of channel and studding further accelerated the process, with any off cuts being repurposed.

Producing the brackets off-site proved far more efficient in terms of cost, time, and waste reduction, but it also significantly reduced the burden on the contractor, allowing them to focus on other aspects of the project. 

Delivering The Kernow-How

Early engagement with Kernow was crucial as it enabled the contractor to call off batches of brackets as required. With a clear understanding of their needs and timeline, we scheduled production of the brackets and studding assemblies in advance. This helped keep the project moving at pace as brackets could be requested, delivered and installed in quick succession.

As with many Central London sites, N2 Nova East had limited unloading space, double red lines and tight delivery windows. With Kernow’s delivery service and close coordination with the contractor, all components were booked in and delivered exactly when required.

Conclusion

Off-site fabrication was a key contributor to the success of this project. By shifting bracket production away from the constraints of the site, the contractor benefited from significant labour cost savings, a streamlined installation process and precise deliveries. This not only helped meet a demanding project timeline but also reduced on-site complexity and risk.

If you think off-site fabrication could benefit your project, do get in touch, or see our pre-fab brochure.