This document discusses offsite construction and modular building. It provides examples of past and present uses of offsite construction including timber frame housing during the Industrial Revolution and modular steel frame construction of the Empire State Building. Barriers to wider adoption are identified as well as benefits such as predictability, quality, safety and sustainability. Case studies are presented across various sectors including housing, commercial, infrastructure and public buildings to illustrate cost and time savings from offsite construction approaches.

1. helpdesk@construction-productivity.co.uk Cited-Richard Ogden – Chairman Buildoffsite
htt://www.construction-productivity.co.uk

2. £2-6 billion
up to 6% of total
UK construction
market
growing at 25% a
year
insitu
construction (94%
market share)

3. It is not new Timber frame housing
Industrial Revolution –
railway terminals,
Crystal Palace
Post war reconstruction
– System housing
driven by acute housing
shortages

4. Modular assembly type
construction – sections of
the steel frame were
prefabricated offsite,
transported into the city and
lifted into position
Empire State
Building (1930)

5. 381 metres 102
storeys high
•Took 1 year and
45 days to
complete
A big issue
today-
sustainability

6. Barriers
Mostly small
companies
limited
resources
Lack of
knowledge
No effective
industry
coordination
Fragmented

7. An assumption that offsite solutions :
1- have failed in the past
2- are mostly housing
- are inevitably more
expensive than traditional

8. • Few
exemplars
• Limited experience of offsite
- among industry professional
- no much exposure at
universities.

9. 1-Predictability
2- Short construction times
3- Right first time quality
4- Less waste
5- Improved health and
safety
6-Noise reduction
7-- Sustainable
8- Relocatable assets

10. Appropriate to
both new build
and refurb
A clear business driver
- Investment to support expansion

11. - Step change in
performance and value
-Global warning and a
demand for sustainable
construction
Demand for MMC by the
public and private sectors

12. - Price certainty
- Quality (snag free)
-90% complete
offsite
- Reliable completion
times

13. -Benchmark
-Benchmarking
- Knowledge transfer
Supply chain-No
contract (PPC2000-TPC
2005)
Continuous
improvement by
working
Cost reduction
Defect free product
100% customer
satisfaction

14. Raising standards
Unique organisation for
change
Focus on offsite solutions • Bringing the whole industry
together

15. Collaborative working – public and private sector
Working for a better built environment
Independent and authoritative
source of information
Growing the offsite market
share
Delivering client value
•

16. Public and private sectors
• Housing & Residential
• Commercial & Retail
• Civil & infrastructure
• Schools, hospitals & MOD
• Sustainability in practice
• Building services in all sectors

17. Unique members partnership
• One to one collaboration with clients
• Understanding client requirements
supply chain
The process:

18. Creating innovative offsite solutions
• Step-change in client value
• Delivering shorter programme times
• Cost effective solutions
B&Q, GSK, Kier
Partnership Homes etc

19. •Raising awareness
•Technical issues
•Problem solving

20. •Cross industry innovation
•Raising profile of offsite
•Offsite is not a “skunk works”

21. •Share best practice
•To grow market share
•Offsite construction and MMC

22. £2k-£22k
• All shapes and sizes
• Off the shelf

23. • Private client
•Volumetric
• 6 units in 3 days
• One off (mass customisation)
• Traditional solution.
£320k-£450k
• Budget 250m2 = £250,000
• Cost neutral

24. Offsite overnight
• 2,700 tonnes
• 200m long
• 65% of BAA work offsite

25.  PeabodyTrust 1999
 30 apartments
 5 floors
 Volumetric light gauged
 galvinised seal
 Architectural awards
 28 weeks earlier
 No brick no scaffolding
 80% solution

27.  • Hybrid (concrete, steel, timber)
 • 2/3 storey factory made
 • 400 units a year
 • First year’s utility bills free!

28.  First in Europe
 Second in world
 £21 million
 17 months off 3 year
 programme
 42 units
 2 storeys
 Fully fitted

29.  mm tolerances
 5 new treatment rooms
 Fitted in 2 weeks
 Made in Canada
 Relocatable (sustainable)
 Depreciated as equipment

30.  • 60,000 sq m office
 • M+E taken offsite
 • - 8.6% cost reduction
 • Build offsite case study

31.  • 30 new facilities world wide
 • 4 in the UK
 • 36 months to 3 months
 • NEWWAY / IKEA
 • 9 basic components

32.  200,000 sq ft
 2 floors of retail
 Car parking on
 ground floor
 3 storeys
 Solar
 Geo thermal
 £25 million scheme
 Section 106 housing
 Centre town location

33.  Busiest international airport in the world
 £4.2 billion project
 Positioned overnight
 £50m
 Radio controlled
 50 tonnes
 87m high
 Foster design

34.  Hot rolled steel frame
 Concrete centre core
 Tallest modular structure in Europe
 1,060 units for 1000 students and
 key workers
 5 buildings
 20 months on site
 1 year saved
 Champion
 £200 million turnover
 Steel / timber

35.  12 units
 Supply 22% of UK energy
 10 decommissioned
 2 closed down 2012
 25 years to 10 years
 10 replacements required
 Can offsite deliver
 Faster, safer
 Toshiba
 AP800 / AP1000

36.  London Borough of Richmond
 Design led
 No boxes
 £350,000
 Mass customised
 1 of 12 classrooms
 BSF for DFES

37.  11,000 components
 Rebuild every 2 weeks
 Micro mm
 75% changed
 £260 million budget per annum
 Project integrator

38. Installation
Photo shows a first floor module being positioned.