Castlebrook worked closely with Pierre Yves Rochon and Studio Urquiola to develop & engineer the fit out of 24 suites of The Emory, a 5-Star, all suites hotel in Belgravia. The £1.2M+, 130ksqft fit out commenced on site for Castlebrook Oct 23 & completed Sept 24.

Castlebrook was contracted to manufacture and install all fitted furniture and wall panelling in the bedrooms and corridors. Originally planned to start early 2022, the rooms layout was completely redesigned reducing the total rooms number and increasing the square footage for each of the 24 suites. The early-stage design process was critical to the execution and success of this project. It involved close, regular consultation with the design teams reviewing the best process for furniture manufacturing to achieve both the visual aesthetic and practical on-site installation. The project involved the interior fit-out of 24 hotel suites and corridors across 3 levels. Castlebrook worked very closely with the main contractor Piperhill, Rainey & Best and the electrical contractor Stothers coordinating the fitting of panelling and casegoods. Each level incorporated distinct wall finishes to meet the design intent and brand standards. All walls within suites and corridors on level 1&2 were fully upholstered using approved fire-rated materials. Wall panels were customised on site to fit perfectly and to receive lights control and power outlets. The designs were very exacting with all casegoods manufactured off site in our factory and then brought to site, having to fit to millimetre tolerances. Suite and corridor walls on level 3 have been finished with high-grade Oak veneered and ribbed solid panelling, seamlessly incorporating concealed access panels where required and built in casegoods and joinery items. The hotel, a new build, is in a very congested area within Belgravia. Delivery and distribution were complex as all products were required to be unloaded externally on the ground floor and transported vertically from one designated point via external hoists, scaffolding and cranes and dispersed to the appropriate floors throughout the building. Our team of experienced installers navigated through the congested site to take the goods to the final location, where they were set out and installed, in sequence and in coordination with Piperhill, Rainey & Best and Stothers.

Achieving seamless finishes within tight spatial tolerances was critical. This would not be possible to achieve in construction with finished furniture. We collaborated closely with the design team to develop a bespoke detail incorporating a concealed tolerance zone. This design allows for subtle movement within the installation, effectively bridging any variation in the built environment while maintaining clean, crisp panel alignments without compromising on the aesthetic or quality of the finished product. Similarly, upholstered panels traditionally present a fixed, non-adjustable finish, particularly at critical junctions like mitred corners. To address this, we engineered a method to integrate tolerance directly into these mitres, allowing us to absorb site discrepancies without the need for reworking or compromising the integrity of the upholstery. This advancement ensures consistent detailing across rooms, regardless of underlying variation. These innovations not only improved the speed and accuracy of on-site installation but also enhanced the durability and long-term performance of the interior finishes, delivering a high-quality guest experience with lasting precision.

Hotel interior projects involving two distinct design languages and materials, (upholstered finishes on lower levels/ timber panelling on upper), present several unique challenges. It’s equivalent to working on 2 separate hotels simultaneously: different drawings, materials, fire ratings, behaviours, installation requirements. Upholstery and timber panelling require very different installation techniques/specialists, increasing complexity in scheduling, coordination and quality control. Timber panelling on level 3 cladded the walls hiding incorporated wardrobes and minibar units. Entrance and other interior doors were supplied by a different contractor. Castlebrook had to work closely with them maintaining a seamless interface between its panels and the doors with almost no gap between them and with a disappearing effect

“Castlebrook is a valuable partner, thanks to its reliability, continuous attention to detail, great flexibility, as well as its understanding of design and its search for technical and aesthetic solutions. Their collaboration has greatly contributed to meeting the standards required by the PYR agency and fulfilling the high demands of a hotel like The Emory”. Sami Tamouza Project Director, “Castlebrook has proven to be an outstanding and trusted partner throughout the development of our project. Their consistent reliability, combined with a sharp eye for detail and a remarkable sense of flexibility, has allowed us to navigate even the most complex challenges with confidence. What truly sets them apart is their ability to seamlessly blend creative thinking with technical expertise, always offering thoughtful and tailored solutions that elevate the overall quality of the work. Their dedication and collaborative spirit have been instrumental in aligning with the project vision, satisfying demanding expectations, and upholding the high standards required by both the design team and client”. Studio Urquiola

Client: Maybourne Hotel Group, Ben Weston; Quantity Surveyors/PM: Rainey & Best, Darren Carlisle; Architects: Richard Rogers (Building) + Blair Associates (interiors) Anna Wolkowicka; Designer Level 1&2: Pierre Yves Rochon, Sami Tamouza, Designer Level 3: Studio Urquiola, Patricia Arbesu; Contractors; Piperhill Construction Ltd, Paddy O’ Neill; Furniture Fit Out Contractor: Castlebrook, Max Piccolo