Panelised Building System Development

Project: Lundell Steel Ltd

Development and digital coordination of a high-performance, panelised building system using innovative thermally broken steel profiles, factory-manufactured panels (open or closed), and full BOPAS accreditation for market readiness.

As offsite and MMC (Modern Methods of Construction) gain increasing traction, Lundell sought to deliver a panelised system that combines structural robustness, thermal efficiency, non-combustibility, and lender-friendly accreditation. The objective: a scalable, repeatable system suitable for diverse building types, with consistent quality and performance.

The Challenge

1. Transforming a concept into a production-ready MMC system

Lundell’s ambition required more than occasional bespoke panels. They needed a system that could be manufactured at scale, with consistent tolerances and predictable thermal and structural performance - underpinned by robust digital data and workflows.

2. Balancing structural, thermal, safety and regulatory demands

The system had to deliver:

• Structural strength via steel framing

• Thermal efficiency via thermally broken profiles (improving U-values, reducing thermal bridging)

• Non-combustibility (steel-based, avoiding timber / combustible materials)

• Accreditation under BOPAS to assure lenders, warranty providers, valuers and future owners of long-term durability - essential for mortgageability and mainstream acceptance.

  
  

3. Building a robust BIM & automation ecosystem

To deliver reliably, the system needed a comprehensive BIM library, data standards, and design automations; ensuring every panel, every interface, every variation could be managed digitally before any physical production.

Our Contribution

System Development & Detail Engineering

We worked alongside Lundell to fully develop the panelised building system:

• Specifying the thermally broken steel profile geometry, optimising for thermal performance without compromising structural integrity. This ensured the system could deliver significantly better U-values than standard light-gauge steel profiles.

• Defining modular panel formats (open panel, closed panel, kit-of-parts or large-format walls), enabling flexibility for different project requirements: from high-volume housing to bespoke schemes.

• Rationalising assembly sequences and interfaces to maximise manufacturability and repeatability, applying the principles of Design for Manufacture and Assembly (DfMA).

• Designing for non-combustibility and compliance; steel framing, controlled manufacture, robust detailing, ensuring the system met stringent safety and building standards.

  
  

BIM Library Creation & Digital Automation

We established a full digital ecosystem to support the system:

• Developed a comprehensive BIM library covering all standard panel types, profiles, interface details, components, and configuration options.

• Built in data structures aligned with manufacturing and assembly workflows, enabling accurate, coordinated information flow from design to factory to site.

• Implemented design automation tools (parametric modelling, automatic panel breakdowns, variant generation) to allow rapid generation of project-specific drawings and BIM models, without sacrificing quality or compliance.

• Ensured digital validation - clash detection, thermal performance simulation, fire and structural checks - before manufacturing begun, reducing risk, waste, rework and surprises.

  
  

Accreditation Support for BOPAS

We guided the system through the accreditation process under BOPAS:

• Documented and formalised the full system lifecycle: design, manufacture, assembly, installation, maintenance - as required under BOPAS standards.

• Demonstrated structural durability, process consistency, manufacturing controls, materials quality and thermal/energy performance in alignment with BOPAS requirements - giving lenders, insurers and future buyers confidence that the system delivers a building life expectance in line with conventional construction (at least 60 years).

• Enabled the “system” rather than just bespoke builds to gain accreditation, meaning any building using Lundell’s panelised system inherits BOPAS status - opening paths to mortgageability, mainstream adoption, and trust in MMC.

  
  

Outcome & Impact

Scalable, market-ready MMC system

Lundell now possesses a fully developed, factory-ready panelised building system - flexible (open or closed panels, varying widths), thermally efficient, non-combustible, and compliant. This system enables clients to adopt MMC with confidence in quality, performance, and long-term viability.

Less components - lower cost

Lundell external wall panels don't need to be wrapped in an additional layer of insulation. Everything is within the steel panel. This means less components in manufacture, no helping hand brackets required for external cladding, its simpler, faster and more robust than other forms of Light Gauge Steel construction.

Reduced risk, improved quality and faster delivery

Through thoughtful system engineering, BIM automation and accredited processes, the variability and uncertainty often associated with non-traditional construction are substantially reduced. Builders and developers can rely on predictable lead times, consistent performance and high quality across repeated units.

Enhanced sustainability and compliance

The use of thermally broken steel profiles improves thermal performance (lower U-values, less thermal bridging), reducing operational energy demand. The steel is recyclable, non-combustible, and manufactured under controlled conditions - contributing to reduced waste and lifecycle resilience.

Accelerated mainstream acceptance of MMC

Thanks to BOPAS accreditation, buildings using this system become more acceptable to lenders, valuers, insurers and end buyers. This helps close the credibility gap between MMC and traditional construction, supporting greater adoption of offsite, modern methods.

Demonstration of digital-first design leadership

By building a rigorous BIM and automation backbone, the project showcases how MMC can be underpinned by digital certainty, not just speed or cost savings. It underlines a philosophy central to by Design: that good design, intelligently coordinated and digitally managed, builds better systems and better buildings.

What This Represents: A by Design Perspective

This collaboration exemplifies exactly why a systems-driven, digitally enabled approach is essential for modern construction. Where traditional build often invites uncertainty, waste and inefficiency, a well-considered panelised system; developed carefully, managed digitally, accredited independently; delivers clarity, repeatability, quality and long-term value.

It underscores our belief: Design That Builds Better.