Context

This research project uses an interdisciplinary knowledge base centred on manufacturing techniques, and employs practices from other industries. By doing so, it consciously seeks to address current difficulties in the building construction industry. These difficulties were clearly identified in the most recent review of the UK construction labour model, produced in 2016. The Farmer Review of the UK Construction Labour Model identifies critical symptoms of failure and poor performance in the UK construction industry, including: low productivity; low predictability in workforce size and demographic; structural fragmentation; lack of research, development and investment in innovation; and poor industry image. Traditional construction is acknowledged by Farmer as too site-based and reliant on the assembly of small components, such as bricks, timber joists and other elements, in a messy environment rather than the controlled setting of a factory as in other industries.

There is a range of alternatives to this model, from the volumetric construction of prefabricated pod-type elements to the use of large cross-laminated timber panels. Many of these are, however, factory-based versions of conventional building-construction systems. Kew House differs from conventional building-envelope construction, which is typically detailed by a build-up of rainscreen elements, waterproofing, structure, insulation, vapour-control layers and internal finishes (15). The structural shell used in the constuction of Kew House allows for a simple, prefabricated sandwiched panelling system.

The choice of Kew House’s structural shell emerged from research into modular manufacturing that extended beyond architecture. An analysis of metal production methods in other industries showed that modular building of chassis, fuselages, ship hulls and train carriages is common. The structural shell of these objects is closely aligned to the finished form. They are effectively self-supporting shells in the form demanded by their function. The idea of a structural shell is well understood and used in the automotive and similar industries, for example in rolling stock production.

The number and size of modules that vessels and vehicles are subdivided into is mainly dependent on the constraints of transportation logistics. Units that work within the size constraints imposed by road or rail transport can be fabricated as one whole. Subdivision is necessary when the size of the project is larger than applicable transportation limits. Transport logistics would also prove crucial in determining the size of Kew House’s roof panels.

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15 Typical domestic house construction.

16 Module of a ship, HMS Prince of Wales, in transit.