maximizing off-site modular construction using lean...
TRANSCRIPT
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Maximizing Off-Site Modular
Construction Using Lean Tools
RJ Reed & Matt Vanture
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Whiting-Turner Contracting Company
#BIM&Prefab
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#BIM&Prefab
BUILDING
INFORMATION
MODELING
PREFAB &
MODULAR
BUILDING
ASSEMBLIES LEED &
SUSTAINABLE
CONSTRUCTION
LEAN PROJECT
DELIVERY
& IPD
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W-T Prefab Group
#BIM&Prefab
Formed in 2011 :: Mission Statement-
To create a resource within Whiting-Turner that
will help everyone understand the potential
benefits of prefab and modular construction.
Industries with Prefab Opportunities
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W-T Prefab Group
#BIM&Prefab
What can we build off-site?
What can we modularize?
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Grand Floridian Expansion
#BIM&Prefab
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Structural System
#BIM&Prefab
Precast structure could
reduce schedule from
25 weeks to 7
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Overall Framing Prefabrication
#BIM&Prefab
Modular Restrooms
Conventional Framing
Prefabricated Interior Walls
Conventional Shaft Wall Framing
Prefabricated Exterior Wall Framing
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Co-located vs. Turn Key Pods
RFQ went out to 4
companies:
• Eggrock
• Neopod
• Ameripod
• Kullman
Constructability
concerns:
• Size of pods
• Required depressed
slabs
• No experience with high-
end finishes
• Requires early finish
information to begin
manufacturing
#BIM&Prefab
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Modular Challenges
Size Restrictions
Typ. POD
Manf. Floor
Plan
Grand
Floridian
Floor Plan
#BIM&Prefab
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Modular Challenges
Finishes
#BIM&Prefab
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Model Room
#BIM&Prefab
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Grand Floridian
Modular & Prefab Construction
Move Significant
Work Offsite
Better Quality
Reduced
Punch List
Schedule Benefits
Leverage D/A Partners
Prefabrication
COST
Schedule Benefits
Construct-ability Issues
Procurement
Warranties
Innovation
OPTION #1 – TURN KEY PODS OPTION #2 :: CO-LOCATED PODS
#BIM&Prefab
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Studio Pod
9 Prefab Panels per Pod
738 Total Panels
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Master Bath Pod
15 Prefab Panels per Pod
1,230 Total Panels
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Sequencing
Shaft wall in place
#BIM&Prefab
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Modular Coordination :: OH Connections
POD #2
POD #3
POD #1
#BIM&Prefab
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Stress Analysis
#BIM&Prefab
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Stress Analysis
#BIM&Prefab
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Modular Challenges
Studio Pods
#BIM&Prefab
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First POD Prototype
July 2011 :: POD Prototype #1
#BIM&Prefab
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Fourth POD Prototype
September 2012 :: Pod Prototype #4 / First Run
#BIM&Prefab
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POD Delivery
#BIM&Prefab
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Production Rate
328
0
Warehouse Production
Installation
Maximum Storage
x
y
Production
Installation
#BIM&Prefab
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Warehouse Design
#BIM&Prefab
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Warehouse Design
#BIM&Prefab
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Warehouse Rental
#BIM&Prefab
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Early Metrics
Man Hours to Frame reduced by 12.5%
Man Hours to Hang Wallboard increased by 18.4%
Combined Productivity reduced by 6.2%
#BIM&Prefab
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Metrics
#BIM&Prefab
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Modular & Prefab Summary
Design Assist Shift of Man Power Hours
(Framing & Drywall) Total Hours on the Job 84,100
Prefab Hours 9,600 (just over 10%)
(Plumbing) Total Hours on the Job 22,800
Prefab Hours 2,900 (just over 10%)
(Electrical) Total Hours on the Job 47,490
Prefab Hours 1,900 (just under 5%)
(Mechanical) Total Hours on the Job 19,568
Prefab Hours 7,248 (just over 37%)
(Fire Protection) Total Hours on the Job 5,400
Prefab Hours 120 (just over 2%)
Approx. 12% shift in hours
to Prefabrication
#BIM&Prefab
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Mechanical Systems
#BIM&Prefab
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Roof Elements
#BIM&Prefab
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Roof Elements
#BIM&Prefab
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Roof Elements
#BIM&Prefab
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Food for Thought
Design-Build, Design/Assist & IPD help fuel the possibilities for
prefabrication / modularization.
The BIM tools allow for greater analysis and
execution of prefab opportunities.
Push the envelope –
Don't accept the ways things have always
been done as the metric for what is possible.
#BIM&Prefab