Working alongside Hollington Architects and contractor Gilbert Ash, Keystone designed and manufactured a bespoke prefabricated Brick Feature Corbelled Arch Lintel spanning 6.2 metres. The completed feature arch delivered the appearance of a traditionally constructed masonry arch while significantly reducing onsite labour, installation time and health and safety risks.

The project demonstrates how offsite construction techniques can successfully combine architectural detail with modern construction efficiency.

As one of the UK’s largest hotel chains, Premier Inn required a visually distinctive entrance feature for its new 60-bedroom hotel development in Farnham.

The proposed design incorporated a large span corbelled brick segmental arch above the entrance, creating a focal point for the façade. However, constructing such a feature traditionally onsite presented several challenges.

The size and complexity of the arch would have required highly skilled bricklayers and extensive brick cutting onsite, adding significant time and labour demands to an already fast-paced build schedule. Traditional construction methods would also have increased health and safety risks associated with working at height for prolonged periods.

Keystone’s technical design team developed a bespoke prefabricated Brick Feature Corbelled Arch Lintel specifically engineered for the project.

To ensure seamless integration with the surrounding façade, Keystone received a consignment of the exact bricks being used onsite. These bricks were precision cut into slips and bonded to the structural steel lintel using a BBA approved construction adhesive.

Manufacturing the arch offsite allowed the entire unit to be assembled under controlled factory conditions, ensuring consistent quality, accurate brick alignment and reduced material waste.

The completed 6.2 metre arch was delivered to site as a single prefabricated unit and lifted into place using a crane. This significantly reduced installation time and minimised the requirement for specialist trades and extended working at height.

The finished corbelled arch creates a bold architectural statement above the hotel entrance while blending seamlessly with the surrounding brickwork.

By adopting an offsite prefabricated solution, the contractor achieved substantial programme efficiencies, reduced onsite disruption and improved installation safety. The project also eliminated many of the quality control challenges typically associated with constructing large decorative brick arches onsite.

Key Benefits

• Bespoke 6.2 metre span brick feature arch.
• Reduced onsite labour and construction time.
• Improved health and safety through offsite manufacture.
• Consistent factory-controlled quality.
• Minimal disruption to the fast-track build programme.
• Seamless integration with surrounding brickwork.

The Premier Inn Farnham project highlights Keystone’s ability to deliver bespoke structural and architectural solutions for complex commercial developments.

Through innovative offsite manufacturing techniques and close collaboration with the project team, Keystone provided a feature lintel solution that preserved the appearance of traditional brick craftsmanship while supporting efficient modern construction methods.

The completed entrance arch now serves as a defining architectural feature of the hotel, demonstrating how prefabricated masonry support systems can achieve both visual impact and practical buildability.