prefabrication in the united kingdom bob mears head of … · prefabrication in the united kingdom...

World of Modular 2011

Prefabrication in the United KingdomBob Mears

Head of Sales & Marketing

Mtech Consult

Technical Expertise

Agenda

• History of Prefabricated Construction Technologies

• Typologies

• History of Modular Construction in The UK

• Where is the Modular Industry Now

• Case Studies

– Healthcare

– Retail

– Affordable Housing

– Hospitality

• Questions & Answers

Prefabrication isn’t new……

……….It just evolved

The History of Prefabrication

The Romans

The Romans

•Occupation of England lasted for nearly 500 years. • Defined as the 'art and science of designing and erecting buildings•Castles and fortress builders built as defences•The rigid requirements led to the development of prefabricated components and standard parts. •Timbers were cut to specific sizes.•Grooves were pre-cut ready for fast construction•Blacksmiths produced iron nails in different shapes and sizes.•Concrete was made by mixing a strong volcanic material ( pazzolana ) with rubble and a mixture of limes.


The Iron Church c 1856

The Iron Church c1856

• Florence Nightingale and the Crimea war. • Brunel came up with a solution.• The church was originally intended as a prefabricated hospital• “There is a tradition that the iron building was in use as a hospital in the Crimea, and that Florence Nightingale tended wounded within its walls”.• Troops called it the “Tin Tabernacle“.• Built entirely of cast-iron with painted glass windows.• Queen Victoria worshipped there.• Built originally on recreation ground, now football pitch.• Transferred to Cranbrook Road in 1866, this site being more central.


The Statue of Liberty

The Statue of Liberty

• Gift from the people of France. • Sculptor Frederic Auguste Bartholdi was commissioned to design a sculpture with the year 1876 in mind for completion.

• Alexandre Gustave Eiffel designed the iron pylon and secondary skeletal framework.

• Pedestal was finished in April of 1886. • Arrived in New York Harbour in June of 1885.• In transit, the Statue was reduced to 350 individual pieces.

• Re-assembly took four months. • Dedication on October 28th 1886.• A centennial gift ten years late.

Heathrow Air Traffic Control Tower

• Completed in 2006.

• 3-storey base.

•18-storey tubular steel mast.

• 5-storey cab on top of the mast.

• Provides 360* vision from 82.5m above the runway.

• Placement of the tower was achieved four weeks ahead of programme

Bathroom & Kitchen Pods

Light Steel Frame (LSF)

Timber Frame

Unitised (Finished) Walling Systems

Structurally Insulated Panels (SIPS)

Insulated Concrete Formwork (ICF)

Twin-wall Permanent Formwork

Pre-engineered Mechanical & Electrical Services

Volumetric Modular Construction

Brief history of modular construction in Europe

Brief history of modular construction in Europe

When did it become a permanent build option?

So how did it change into today’s permanent build option?

The Cube

Where is the industry now?

• Europe wide in excess of £4b ($6.4b)• UK modular sector worth > £1.2b ($2b)• 200+ European manufacturers• UK is seen as market leader• Mainly steel based but product takes many forms• Still relatively immature & fragmented supply chain• Better understood with market growing at >20% per annum

• Generally confined to room sized accommodation

• hotels• student residences• residential• education (classrooms)• health (wards)

Case Study - Healthcare

Emersons Green NHS Treatment Centre

• Purpose-built surgical hospital providing a range of elective surgical services, including inpatient treatment to NHS patients. • Operated by UK Specialist Hospitals (UKSH).• The £13m ($21m) project is believed to be the largest complete hospital to be built using off-site construction and was completed and opened in November 2009.

On Time & On Budget

• A sustainable approach to construction • Co-ordination of design requirements across a wide range of specialist areas and the design and installation of highly complex M&E services

• Co-ordination of specialist subcontractors to maintain programme

• Excellent communications with the client throughout• Outstanding site management.

• An innovative approach to construction that minimised on-site working and reduced the programme time.• Stringent compliance with NHS technical requirements.

Challenging Programme

Watertight as fast as possible. Within just four weeks of

Yorkon’s contract award, the infrastructure works had been completed ready to receive the specially manufactured modules.

• The three-storey 4,842sqm (52 000sq ft) building comprises 114 steel modules up to 14m (46ft long).• Craned into position in just three weeks to reduce the build time to only 12 months. • The programme was critical as patients were booked in for treatment.• Some areas of the building were handed over at an earlier stage. Yorkon revised the fitting out programme to accommodate this client requirement.

Communication & Site Management

• The speed of offsite construction requires faster decision-making.

• A good relationship and close communications between Yorkon and UKSH were essential to the success of the project.

• Outstanding site management. site management team was recognised with Considerate Constructors ‘Performance Beyond Compliance’ certification. • Health and Safety. There were no accidents on site for the duration of the project, more than 120,000 man hours.• Flexible approach to design. Despite the earlier decision-making required for off-site construction, Yorkon was able to accommodate the client’s design revisions.

Integrating Offsite & Traditional

Traditionally Constructed Atrium

Healthcare - Emersons GreenNHS Treatment Centre

A Sustainable Approach

Retail

Tesco Store Southam

Retail – Tesco Store Southam

New Modular Store Design


Reducing Waste On Site


Reduced Carbon Footprint


Staff Facilities

Affordable Housing – Evolve

St Johns Way


Time Plan


Environmental Impact


Measured Heat Loss


Key Points

Hospitality

Premier Inn - Oswestry

Hospitality – Premier Inn Oswestry

Room Modules


Speed Of Build


Corridor Modules


Internal Finish

The Benefits of Using Pre-fabricated

Construction Technologies

Or Offsite

Benefits

• Reduced Construction Time

Benefits

Benefits


• Earlier Profitability

• Higher Quality Finish

Higher Quality Finish

Familiarity Breeds Regularity

Benefits




• Centralised Control

Centralised Control

For example, pods

• Plumbing

• Tiling

• Electrical work

• Carpentry

• Stone masonry

• Glazing

Benefits





• Health & Safety

Sustainability

Sustainability

• Factory waste is typically less than 1.5% compared with more than 10% on a traditional construction site

• Factory operatives are 300% more efficient

• Potentially 90% fewer vehicle deliveries

• Factory operative travels 2 miles to work and the national average is 8.5 miles

Benefits





• Health & Safety

• Sustainability

• Less Risk

• Less Construction Disruption

• Less Demand on Resources

• Potentially Less Design Time

• Permanent Skilled Workforce

Permanent Skilled Workforce

Disadvantages

• Relies on early planning

• Greater level of coordination

• Getting it wrong can be a big issue

• Cost beware!

Questions & Answers

Questions & Answers

Thank You For Your Attention

Bob MearsHead of Sales & MarketingMaple HouseThe Professional QuarterShrewsbury Business ParkShrewsburyShropshire SY2 6LG

Phone +44 (0)1743 282282Fax: +44 (0)1743 357367

[email protected]

www.mtech-consult.com

prefabrication in the united kingdom bob mears head of … · prefabrication in the united kingdom...

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