Proposal VITHAUS x StikBilt
23 October 2020
Proposed for Aslan Ghods Nahri Managing Director of StikBilt Parkville, VIC 3010 Prepared by Nesia Cahyono VITHAUS Latvia, LV 1009 vithaus@gmail.com
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Executive Summary StikBilt is the largest construction company that focuses on building detached house in Australia Being in the industry for more than twenty years, StikBilt is still implementing a traditional construction method in building its standard house. On the other hand, VITHAUS is a relatively new European-based construction company that is specialised in providing instant houses through modular prefabrication. Following its expansion plan to Australia, VITHAUS is proposing a partnership with StikBilt. In this proposal, VITHAUS introduces KOBEHAUS, the StikBilt’s standard house which is prefabricated in the factory. Mutual benefits will be obtained as VITHAUS is sharing its technology, and StikBilt is using its dominance in Australian market to get clients. The effectiveness and efficiency of using modular prefabrication results in higher profit and other benefits. By implementing KOBEHAUS, a partnership between StikBilt and VITHAUS is projecting profit.
KOBEHAUS A combination of KOSHAUS and CUBEHAUS, which is a prefabricated pitched-roof and flat-roof house, respectively. KOBEHAUS is prefabricated with the highest prefabrication degree; module.
KOBEHAUS
3 modules of KOSHAUS
+13%
profit on top of the StikBilt’s initial profit
$35,412.11 total net profit for each standard KOBEHAUS being sold to the market
100%
2 modules of CUBEHAUS
106 days 87%
~ 100% TIME
42 days living space
garage
Hit the breakeven point in less than 24 months.
VITHAUS x StikBilt
~ 40%
StikBilt COST
KOBEHAUS
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Table of Contents Executive Summary............................................................. 2 Table of Contents.................................................................. 3 About Us: since 2002............................................................ 4 Our Specialisations..................................................... 4 Introduction............................................................................. 6 Proposal .............................................................................. 7 1.0 Proposed Technique....................................................... 8 KOBEHAUS...................................................................... 8 Member Schedules...................................................... 14 2.0 Construction.................................................................... 18 2.1 Prefabrication in Factory..................................... 18 Special Connections...................................... 21 Prefabricated Modules.................................. 22 2.2 Site Preparations................................................... 24 2.3 Transportation........................................................ 26 Regulations....................................................... 27 2.4 On-site Assembly................................................. 28 Special Systems.............................................. 30 Stitching............................................................. 31 3.0 Why KOBEHAUS?............................................................ 32 3.1 Benefits of Prefabrication................................... 32 3.2 Benefits of VITHAUS............................................. 33 3.3 Faster Construction.............................................. 34 3.4 Cost Effective.......................................................... 40 Cost Breakdown.............................................. 41 Initial Capital Costs........................................ 42 Financial Feasibility....................................... 43 Benefit-Cost Analysis................................... 44 4.0 Barriers: KOBEHAUS..................................................... 45 5.0 Conclusion........................................................................ 46 6.0 List of Appendices......................................................... 47 7.0 References....................................................................... 55
VITHAUS x StikBilt
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About Us since 2002 Change the way you think about house construction.
VITHAUS is one of the leading prefabrication companies in Europe. Our passion is in providing instant houses for the community. It is always under our concern that the houses are of high quality and environmentally friendly. In the past decade, we have been extending our branches to six areas in Europe: Austria, Latvia, France, Netherlands, Spain and Portugal. Through these cities, we supply instant houses to most of Europe (VITHAUS 2020). 3%
Our Specialisations
total market in Europe Union
design, manufacture, sale Our specialisation is in providing ready-to-live detached houses in a short time. We prefabricate timber modular houses according to our standard projects: KOSHAUS and CUBEHAUS, and assemble them on site. Our house comes in a full package consists of utilities and furniture. They are designed to perform in four different climates. KOSHAUS KOSHAUS is a standard house with pitch roof. There are five sizes available: » » » » »
KOSHAUS 26 KOSHAUS 53 KOSHAUS 78 KOSHAUS 106 KOSHAUS 132
CUBEHAUS CUBEHAUS is a standard house with flat roof. There are two sizes available: » »
CUBEHAUS 80 CUBEHAUS 93 Figure 01. VITHAUS’s past projects Source: VITHAUS, 2020
VITHAUS x StikBilt
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2020 The year of pandemic
26% total market in Europe Union
01 05 01
This year, people are restraining themselves from spending money on non-urgent expenses. All industries are affected, no exception for the construction industry. However, we like to see this condition from a different perspective. After the pandemic is over, we believe the economic growth will be followed by a huge leap in residential housing demand. Our in-house R&D team believes there is a promising opportunity in Australia’s market, especially Victoria. The underlying reasons are the population demographic in the regional area as well as the severity of the pandemic within the state. As the pandemic is still an issue, we are seeing this as a perfect time to settle down in Victoria. We are hoping that by the time the pandemic is over, we are ready to deliver our service to the local community. Following our expansion idea to Victoria, we are intending to collaborate with a local construction firm to familiarise ourselves with the local environment. As a leading residential builder in Australia that shares the same values of quality and sustainability, we believe StikBilt can be our partner in Australia. We are confident to achieve a success in our collaboration due to our affordable price and our advanced techniques that are suitable for Australia’s climate.
headquarter branches proposed branch in Victoria
VITHAUS x StikBilt
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Introduction
This report serves as a proposal for StikBilt to collaborate with VITHAUS. We will be introducing a new technology in building houses that will be the interest of Australian community. This report will cover six sections as follows:
Proposed technique This section introduces the products that we are proposing
Construction This section describes the prefabrication, transportation and installation processes Benefits This section provides evidence on time and cost reduction in implementing the proposed design Limitations This section covers the limitations of the proposed technique and how it will have impacts on projects
Conclusion This section wraps the report by highlighting the important points
VITHAUS x StikBilt
1 2 3 4
5
1 2 3 4
5
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Proposal
Upon our decision to do expansion to Australia, our internal team has been conducting a further study as part of the process. The findings and suggestions are listed below:
Australia is seen as a suitable area of expansion. One of the reasons is the high indulgence factor in the country. According to Hofstede (2020), Australia scored 71 out of 100. This factor describes Australia as a country with a community that has weak control over their impulses and desires to enjoy life. Therefore, it is expected that housing demand will significantly increase once the pandemic is over. Greater Melbourne is the most suitable area to establish the first branch in the southern hemisphere because of two reasons. Firstly, Victoria is still in the lockdown stage (Victoria 2020). It will be a perfect time for us to get everything ready. Secondly, Melbourne is the capital city of Victoria, and is the second most populous city in Australia (Glenn 2018). For efficiency, it is suggested that VITHAUS cooperates with local construction companies in order to lower the barriers of entry to the industry. StikBilt is seen as a suitable local builder to collaborate with. Established in 1999, StikBilt is an experienced builder that is specialised in building houses across Australia. StikBilt has been expanding to three states: Victoria, New South Wales and Western Australia. Very similar to VITHAUS, StikBilt has a standard housing design to build. However, StikBilt is still using traditional construction techniques for all projects, while VITHAUS is using the standard projects to achieve economy of scale in the factory. VITHAUS and StikBilt undergo a partnership relationship by providing one door housing solution to Australian market. In this collaboration, VITHAUS and StikBilt bring mutual benefits for each other. VITHAUS introduces the effective prefabrication technique to StikBilt, while StikBilt shares its excellent branding exposure in the Australian market to VITHAUS.
Based on these five points, we are proposing a partnership collaboration with StikBilt. We believe that our collaboration will be successful, especially with the unprecedented technique we are offering to Australia. The detail of the technique is elaborated in the next section.
VITHAUS x StikBilt
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1.0
Proposed Technique KOBEHAUS VITHAUS’s main business is manufacturing modular prefabricated buildings. Dissimilar to the normal design-driven modular buildings, most of our products are on-shelf designs. In Europe, we have two standard projects: KOSHAUS and CUBEHAUS. The former is a pitch house, while the latter is a flat-roof house. Each of them has a few further options depending on the size of the land and the number of bedrooms (VITHAUS 2020). In collaboration with StikBilt, we proudly present KOBEHAUS as a new standard project in Australia. It is a new design that well represents StikBilt’s standard house. By combining our signature KOSHAUS and CUBEHAUS, our highly experienced designer comes up with KOBEHAUS. This section will display the StikBilt’s standard house and how our technique will realise the design as a modular building.
StikBilt’s Standard House » » » » » »
Landing and steps Entry Dining room Kitchen Garage Formal lounge
» » » » » »
1 master bedroom 2 bedrooms 1 ensuite 1 bathroom 1 laundry Decking/terrace
Dwelling Area
160.70 m2
Garage Area
41.23 m2
Terrace
27.68 m2
Landing & Steps
8.70 m2
Site 733.00 m2 Rooms 3 Dimensions (m)
VITHAUS x StikBilt
15.20 x 13.29 x 3.70
Depart from these specifications, we guarantee that KOBEHAUS will come with similar configuration plus a high and uniform quality across all products. We have our reliable supply chains working with us to provide all consumable and non-consumable materials.
LANDING & STEPS 8.7m2
FORMAL LOUNGE 21m2
MASTER BED + ENSUITE 18 + 3.20 m2
BATH 6.3m2
ENTRY 7.21m2
GARAGE 41.23m2
KITCHEN 12.65m2
BED 2 15.40 m2
DINING + FAMILY 19.00m2
BED 3 10.38m2 L’DRY 3.77m2 TERRACE 27.68m2
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Figure 02. Impressions of StikBilt Standard House Source: illustrated in Revit
Building Area
152.57 m2
Useful Area
160.70 m2
Dimensions (m)
15.20x 13.29 x 3.70
Ceiling Height
2.10 - 3.27 m
Rooms 3 Terrace
27.68 m2
Prefabrication
33 days
Price
152,551.38
KOBEHAUS is a combination of KOSHAUS and a modified CUBEHAUS. The modification is undertaken to redesign a dwelling house of CUBEHAUS into a garage. In this combination, KOSHAUS will be used to fully cover the Dwelling area, while the CUBEHAUS will be used to fully cover the Garage area. The Decking and Landing & Steps area will be constructed on site with pre-cut materials. The Deck and Landing & Steps are designed to be semi open. KOSHAUS and CUBEHAUS will be produced in similar materials to minimise distinct material movements due to temperature or weather exposure. At every connection, control joints will be introduced, and wherever required, expansion joints will be installed. Details of the joints will be illustrated in the section 2.1 Prefabrication in Factory.
VITHAUS x StikBilt
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Figure 03. KOSHAUS Source: VITHAUS, 2020
1.1 KOSHAUS Pitched roof modular house. KOSHAUS is a spacious house with net lettable area of 152.57 m2. By default, the house consists of: » » » » » »
Landing & steps Entry Dining room Kitchen Garage Formal lounge
» » » » » » »
152.57 m2
Dimensions (LxWxH)
16.30 x 9.36 x 3.70 m
Ceiling Height
2.10 - 3.27 m
Rooms
4 bedrooms (no master bed)
Terrace 40 m2 Prefab + delivery
KITCHEN 11.15 m2
TERRACE 40 m2
STORAGE 7.94 m2
ENTRY + DINING + FAMILY 43.85 m2
BED 2 25.85 m2 BED 4 11.94 m2
The garage will use CUBEHAUS. Figure 05. Plan of KOSHAUS Source: VITHAUS, 2020
VITHAUS x StikBilt
BATH 9.92 m2
BED 1 25.85 m2
160.70 m2 Ensuite Formal lounge
* price is from VITHAUS’s website
120 - 150 days
Price* $90,000 - $110,000
1 master bed 2 4 bedrooms 1 ensuite 1 bathroom 1 laundry Terrace 1 storage room
To mimic StikBilt’s standard house, some changes will be made on KOSHAUS: 152.57 m2 area Storage room 1 bedroom
Building internal area
BED 3 10.93 m2
L’DRY 6.12 m2
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Figure 04. CUBEHAUS Source: VITHAUS, 2020
Building internal area
65.42 m2
Dimensions (LxWxH)
11.00 x 9.40 x 3.15 m
Ceiling Height
2.50 m
Rooms
2 bedrooms (no master bed)
CUBEHAUS
Terrace 18.30 m2 Prefab + delivery
Flat roof modular house.
120 days
Price* $70,000 - $90,000
KITCHEN 4.79 m2
BATHROOM 4.55 m2
L’DRY 3.59 m2
ENTRY 3.60 m2
Figure 06. Plan of CUBEHAUS
BED 1 10.00 m2
CUBEHAUS is designed to be a compact house with a liveable area of 65.42 m2. The spaces in the house including: » » » »
Landing & steps Entry Kitchen Living room
» » » »
2 bedrooms 1 laundry 1 bathroom Terrace
To complete the StikBilt specifications, CUBEHAUS will be modified as follows:
DINING + FAMILY 23.32 m2
TERRACE 18.30 m2
1.2
LANDING & STEPS 9.35 m2
BED 2 10.00 m2
65.42 m2 area Landing & steps Dwelling area
41.23 m2 removed Garage
The modified CUBEHAUS will be shown on the next page. * price is from VITHAUS’s website
Source: VITHAUS, 2020
VITHAUS x StikBilt
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Figure 07. Modified CUBEHAUS Source: illustrated in Photoshop
Building internal area
41.23 m2
Dimensions (LxWxH)
6.55 x 6.53 x 3.1 m
Ceiling Height
2.4 m
Modified CUBEHAUS
Rooms -
Garage
Terrace -
The modified CUBEHAUS will share the same appearance with the original CUBEHAUS. The adjustments are made mainly to the size and the interior of the product. The modified CUBEHAUS will be a simplified version of the original CUBEHAUS due to the shift of function from a dwelling house to a garage. The huge reduction in price is because of few reasons:
Prefabrication 30 days
» » » » »
Price* $20,000 - $30,000
GARAGE 41.23 m2
size reduction mechanical removal electrical reduction fitouts removal floor finish removal
Figure 08. Plan of modified CUBEHAUS * price is estimation only
VITHAUS x StikBilt
Source: illustrated in Revit
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KOBEHAUS KOBEHAUS is available in three classes. From the lowest to the highest efficiency classes are Class B, Class A and Class A+ (VITHAUS, 2020). Class B is the default class for KOBEHAUS. Therefore, unless otherwise stated, the word KOBEHAUS refer to as Class B KOBEHAUS. Depending on the clients’ preference, the level of efficiency can be chosen. There is an increase of approximately 10% for one step up of the efficiency level. Table 01. Footing options for KOBEHAUS
Material
Class B
Class A (Class A (add-ons or specs changes)
Class A+ (add-ons or specs changes)
Roof
Metal profiled sheet
- 200mm rock wool thermal insulation
- 12mm fiberboard isoplaat - 250mm rock wool thermal insulation - 10mm gypsum fiberboard - 50 mm rock wool insulation - 1mm dust barrier
- 25mm fiberboard isoplaat - 350mm rock wool thermal insulation
External wall
Metal profiled sheet
- 150mm rock wool thermal insulation
- 12mm fiberboard isoplaat - 200mm rock wool thermal insulation - 10mm gypsum fiberboard
- 25mm fiberboard isoplaat - 50mm rock wool thermal insulation - 1mm dust barrier
Floor
Laminate EGGER
- 200mm ecowool thermal insulation
- 250mm ecowool thermal insulation
-
Windows and entrance doors
Wooden frame
- 78mm wooden frames with double seal circuit
- 90mm wooden frames with double seal circuit
- 106mm wooden frames with double seal circuit
Structure of interior walls
- AB grade pine frame - 100/150mm rock wool thermal insulation - timber cladding with white SIKKENS coating
Electrics
- metal corrugation with PVC insulation - FRLS wiring cable - double positioned, ceramic based socket groups
Network engineering
- 50/110mm PVC pipes for sewerage - 20mm diameter polypropylene pipe - heated floor in bathroom
Additional expenses
- delivery to the building site >150km - 25T crane rental for installation - footings on site
- 100mm ventilation duct in bathroom and kitchen - roof fan riser
VITHAUS x StikBilt
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Member Schedules KOBEHAUS will be sold at a basic price of $192,457.12 (refer to section 3.2) with member schedules as shown below. It has to be noted that neither of these options will change the design of the building. The options will only impact the interior impression of KOBEHAUS. The specifications that are included in the price are marked in bold. Table 02. KOBEHAUS member schedule
Specification Efficiency class
Roof
Facade
VITHAUS x StikBilt
Photo
Price
Class B (200mm floor, 150mm wall, 200mm roof, 78mm windows)
$66,500
Class A (250mm floor, 200mm wall, 300mm roof, 90mm windows, 10mm GSP, 12mm isoplaat)
$73,150
Class A+ (250mm floor, 250mm wall, 400mm roof, 106mm windows, GSP 10mm, 25mm isoplaat)
$80,465
Metal sheet
$12,000
Metal tile
$14,630
Shingles
$19,680
combination of metal profile and pine cladding
$17,600
Full pine cladding
$20,300
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Specification Timber coating
Flooring
Heating
Water heater
Photo
Price
Paint
$7,900
Oil coating
$11,440
Laminate egger
$11,000
Parquet board
$14,100
Coil heated floor
$8,190
Electric heaters
$8,900
Infrared warm floor with temperature regulator
$440 each
50 gal. electric heater
$2,800
VITHAUS x StikBilt
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Specification
Photo
Price
Water heater
50 gal. natural gas heater
$2,970
Air exchange
Channel for heat pump
$3,200
Air to air heat pump
$5,400
Recuperator
$560 each
Bathroom complete set
Standard
$27,700
Premium
$29,750
Garage
with automated roller door
$24,300
Terrace
Open-timber floor
$10,600
VITHAUS x StikBilt
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Specification
Photo
Price
with stairs
$3,000
Canopy with metal roof
$18,000
Additional stairs (1.5m long)
$225/step
Delivery up to 150 km
4 trucks
$0
Over 150 km
$8/km
Installation
Tractor push
$6,000
25-ton crane
$295/hr
Stove fireplace
$2,750
Stove fireplace with marble finish
$4,750
Porch at the entrance
Fireplace
TOTAL PRICE
$200,790
TOTAL PRICE IN PACKAGE (1 KOBEHAUS)
$192,457.12
VITHAUS x StikBilt
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2.1
Construction Prefabrication in Factory
The whole construction process will be conducted in a factory where ergonomics can be achieved with a fully controlled environment. It allows different building components to be manufactured simultaneously, and hence reducing the construction time. The process is as follows (images source: Quality Homes, 2019).
STEP 1
STEP 2
STEP 3
Materials are stored in the factory. Weather sensitive materials such as timber and plasterboard are kept in an indoor environment to minimise deteriorations.
Prefabrication process is started by framing the floor on an ergonomic workbench. The height of workbench is adjustable to facilitate several processes.
The finished floor frame is elevated above the head to ease the installation of underfloor cables and pipes. Floor penetrations are created where required.
STEP 4
STEP 5
STEP 6
The floor with cables and pipes is ready to be installed on a wheeled platform. The entire module will be built up on this platform until it is ready to be transported.
Timber studs are nailed to each other to form timber load bearing walls. The wall is assembled on a workbench, and the process can be conducted parallel with timber framing process.
Timber studs assembly is followed by covering the internal side of the wall with plywood. The external side is not cover for cables, pipes and insulation installations.
VITHAUS x StikBilt
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STEP 7
STEP 8
STEP 9
The drywall is nailed to the pre-installed floor. It is erected with the help of gantry crane in the factory. When wall and floor are assembled simultaneously, the wall can be installed straight after the floor installation process.
Roof trusses are assembled in the factory and then followed by the process of placing them in order on an adjustable platform. These processes can be done in parallel with floor and wall framings. The trusses are held together with temporary battens that run in perpendicular direction.
The platform is elevated above the head for ceiling installation. Before the ceiling is installed, cables, pipes, ducts and insulation are placed on the ceiling on the workbench. The ceiling is attached below the roof with all services already installed.
STEP 10
STEP 11
STEP 12
The roof with ceiling is erected using gantry crane and put in place. The bottom chord of roof trusses are nailed to top plates of the walls.
After the roof is installed, interior works such as drywall taping and mudding can proceed.
Parallel with the interior works, cables and pipes can be placed within the wall from the outside. Simultaneously, roof finishing process can be conducted.
VITHAUS x StikBilt
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STEP 13
STEP 14
STEP 15
Wall insulation is installed from the outside after the cables and pipes installation.
According to the specifications, flooring layers will be installed.
Window and door are produced on butterfly tables to increase the ergonomic.
STEP 16
STEP 17
STEP 18
The outside wall is covered with plywood and then wrapped in building paper to avoid water leakage.
Lightings are installed to facilitate the works inside. The interior work is continued by sanding the wall and applying timber cladding.
Windows and doors are ready to be put in place. The gaps are sealed with foam sealing system and concealed with architraves.
STEP 19
STEP 20
STEP 21
Joinery and services are installed. Between two in-contact appliances, compressive material will be placed to reduce bumps.
Wall cladding is installed only on sides without connections with other modules. Then, exterior wall proofing is wrapped around the module.
The modules are ready to be transported.
VITHAUS x StikBilt
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Special Connections
MMHC Hinged Roof Connector This connection allows pitched roof to be folded flat during shipping. Figure 09. Special roof connection
Source: SIMPSON Strong-Tie, 2020
MMHC hinged roof connector developed by SIMPSON Strong-Tie will be used at the truss connection points to reduce the height of the roof (SIMPSON, 2020). For KOBEHAUS, 4.9 m high module is reduced to 3.5 m. Nail pattern allows nailing on both sides
Off-the-shelf galvanised product
to increase support
Hinged Overhang Connector This custom made connection allows roof overhang to be folded in during shipping.
Three parts to a straight component
Roof finish to be installed on site
Figure 10. Overhang connector
Source: Bob Vila, 2012
Different with MMHC Hinged Roof Connector, this connection enables three components to be folded and unfolded to a straight line. It has to be custom made to match timber size. Customised product
Roof finish to be installed on site
VITHAUS x StikBilt
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The KOBEHAUS will be divided into five modules. Three of them are parts of KOSHAUS and the rest two are parts of CUBEHAUS. However, the number and size of modules can be adjusted according to the site location and the route that will be taken.
Prefabricated Modules
V B
II III
I
IV
A
KOSHAUS A
CUBEHAUS Terrace
B
constructed on site Steps & Landing
Figure 11. Annotated plan of StikBilt Standard House Source: StikBilt, 2020
MODULE I Size Rooms
: 12.578 x 4.871 x 4.9 m : Kitchen, Dining room, Bed 3
Module I is the first module to transport because it has terrace that will be constructed on site. Module III has external walls on three sides which result in minimimal use of extra packaging. Figure 12. Module I Source: illustrated in Revit
VITHAUS x StikBilt
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MODULE II Size Rooms
: 14.754 x 2.273 x 4.9 m : Entry hall, Bathroom
Module II is the second module to be transported and the module with the highest slenderness ratio. This characteristic requires temporary reinforcements to make sure the module is transported in a good condition.
Figure 13. Module II Source: illustrated in Revit
The arrangement of Module I to V takes into account the transport limit in Victoria, as well as material movement due to weather exposure. They are arranged parallel to each other to reduce the possibility of one module interlocks the movement of the other modules.
MODULE III Size Rooms
: 6.546 x 4.793 x 3.1 m : Garage
The garage must be divided into two modules due to the width limit. Module IV has a large opening for garage roller door that needs temporary supports.
Figure 14. Module III Source: illustrated in Revit
MODULE IV Size Rooms
: 6.546 x 1.736 x 3.1 m : Garage
Module V covers the rest area of the garage. It requires temporary reinforcements for transport.
Figure 15. Module IV Source: illustrated in Revit
MODULE V Size : 15.204 x 4.467 x 4.9 m Rooms : Formal lounge, master bed + ensuite, bedroom 2 Module III has the largest volume. Similar to Module I, Module III has walls on three sides. It does not require special treatment due to its ideal size.
Figure 16. Module V Source: illustrated in Revit
VITHAUS x StikBilt
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2.2
Construction Site Preparations
KOBEHAUS is compatible with any types of footings. Few types of footings that are commonly used in combination with our prefabricated products are pier and beam footing, slab footing and basement footing (R. 2020). The selection of footings should consider the type of soil and, the typical weather conditions, and the likelihood of termite at the site. In order to be a one-door solution to our clients, we will provide consultancy and construction services to our client upon request. These services will be directly under StikBilt’s supervision, whom we believe must have a better understanding about Australia’s soil conditions.
Table 03. Footing options for KOBEHAUS
Pier and beam Characteristics
» »
» »
Advantages
» » » » » » »
Disadvantages
» » »
VITHAUS x StikBilt
Slab
concrete stump or timber/ brick/block pier and beam typically used when traditional site-built footing is expected built using poured concrete footers mid range price
»
Seismic resistance Flood resistance depends on the materials Can withstand high wind Suitable for soil with high expansion and contraction Suitable for uneven ground air insulation under the home accessible under floor area
»
Not suitable for hurricane and tornado sagging, creaking mold
»
» »
»
Basement
concrete sit on top of the ground with anchors embedded to the ground Insulated at the perimeter The most cost and time effective
»
Seismic resistance flood resistance
»
» »
»
Not suitable on sloping ground
»
»
concrete wall running along the perimeter of footing can be conditioned or unconditioned the deepest footings
extra living or spaces to your home Seismic resistance
Higher cost due to the construction time and materials longer installation time
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Most often, a combination of pier and beam and slab footings are used to support KOBEHAUS. The pier and beam footings are used under the KOSHAUS for the elevated ground floor. Slab footing is used under the CUBEHAUS for the on-ground garage floor. The construction of slab is started only after Module III is completely assembled. The pier and beam footings arrangement has been matched with the modules so that some piers will be shared between two modules.
Figure 17. Footings 3D view Source: illustrated in Revit
Pier and Beam & Slab Footings Plan
Figure 18. Footings Plan Source: illustrated in Revit
VITHAUS x StikBilt
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2.3
Construction Transportation
The module has been designed so that it can be transported within Victoria. It must be ensured that all preinstalled furniture and services are tied to the wall and compressive materials have been added between two components. This is to reduce damage during transport. The transporting process is displayed below (images source: Modular Transport Canada, 2016).
STEP 1
STEP 2
STEP 3
The module that is going to be transported is put on a trailer deck. Moving the module to the deck can be done by elevating the module’s platform or using crane.
A set of back lightings and caution warning are attached to the back of the module.
A tractor is attached to the trailer, and then ready to go.
STEP 4
STEP 5
STEP 6
In general scenario, no escort is required to transport Module I to V. However, when it is required, it has to be prepared. National Heavy Vehicle Regular (NHVR) also provides the service.
The tractor and trailer are off the factory with pilot(s) when required.
The escort must be directly in front of the trailer at all times.
VITHAUS x StikBilt
D
ON RIGID TRUCKS - GENERAL ACCESS
page 27
6.0t
9.0t
Regulations Victoria has regulations on the size of vehicles that are allowed to use Victorian roads. The regulations 6.0t 16.5t restrict the weight as well as the dimensions. However, as KOBEHAUS is built with lightweight materials, the maximum dimension sets the limit for us. Referring to Victoria’s regulations issued by VicRoads, the maximum dimension of a vehicle with general access is 19.0 x 5 x 4.5 m. Pilots and/or escorts might be required beyond certain dimensions as regulated by VicRoads (see Appendix 5). The requirements for 6.0 20.0t general scenario of KOBEHAUS’s five modules are listed below. Table 04. Pilots and escorts on Victoriaan roads
Module
Size (m)
Pilots
Escorts
I
13.0 x 5.0 x 3.5
2
-
II
15.0 x 2.5 x 3.5
-
-
III
6.8 x 5.0 x 3.1
2
-
V
15.5 x 5.0 x 3.5
1
-
* Comment 10.0t 16.5t
10.0t*
20.0t
2 3 4 4 5
ON SEMITRAILER COMBINATIONS -- GENERAL ACCESS together with Mod. III IV 6.8 x 2.0 x 3.1 -
The selected trailer is 4 axle semi trailers with flatbed. Prior to transporting the modules, authority permit must be received. The permit will states if time restrictions, traffic control or power line works are necessary to travel through busy areas.
6.0t
3 9.0t
9.0t
4 6.0t
9.0t
16.5t
5
Other road factors that may become issues in the transport process are (Westbuilt, 2018):
6.0t Hilly road
Bridge
9.0t
20t
Narrow road
Underpass / tunnel
5 6.0t
16.5t 1.2 m
1.4 m
The best solution to these problems is to adjust the module dimensions.
6.0t
16.5t
1.0 m
1.6 m
Figure 19. 4 axle semi-trailer truck
16.5t
20.0t
Source: National Heavy Vehicle Regulator, 2019
6
ON RIGID TRUCK AND TRAILER COMBINATIONS (Gener VITHAUS x StikBilt
page 28
2.4
Construction On-site Assembly
The modules are designed for assembly using tractor push technique. However, when tight site with diffucult access is encountered, the modules can be adjusted to suit crane lift technique for assembly. The structural elements in each module need to incorporate steel in certain areas to provide strong lifting points for the crane. Table 05. Assembly techniques
Tractor Push
Crane Lift
Characteristics
Low-loader trailer with a folding gooseneck is used to transport the module. The on-site installation is facilitated with a 4WD tractors and drawbar
The module is craned straight from the trailer
Advantages
» Cost effective » Easy » Suitable for off-road sites
» Seismic resistance » Flood resistance
Limitations
» Uneven or sloping sites » Tight site
» More expensive » Additional footing is needed for the crane
FOOTINGS INSTALLATION
MODULE I ASSEMBLY
MODULE II & TERRACE
The type of footings is selected based on the type of soil on site. This process must be finished by the completion of Module I prefabrication.
Module I is transported to site and placed on the footings that have been prepared before.
The construction of terrace behind the building is commenced. Module II is placed next to Module I.
Figure 23. Footings installation
Figure 24. Module I assembly
Figure 25. Module II & terrace
Source: illustrated in Revit
Source: illustrated in Revit
Source: illustrated in Revit
VITHAUS x StikBilt
page 29
Tractor Push Tractor push technique moves the module from the trailer to the designated place by controlling the height of the trailer and the footings. It can be seen from Figure 21, the trailer is elevated. Then, after reaching the final position, the trailer is lowered, leaving the module on the footings. The trailer is then taken out using the drawbar (Figure 22).
1.6 m
Figure 20. Access to assembly Source: illustrated in Revit
Figure 21. Elevated trailer
Figure 22. Trailer is dragged out
Source: Klopp, 2016
Source: Klopp, 2016
MODULE III ASSEMBLY
MODULE IV ASSEMBLY
MODULE V ASSEMBLY
Module III is assembled next to Module I and II. The steps and landing at the entrance is constructed.
Module IV that is transported together with Module III is put on place. Roller door is installed.
Module V is placed next to Module II.
Figure 26. Module III assembly
Figure 27. Module IV assembly
Figure 28. Module V assembly
Source: illustrated in Revit
Source: illustrated in Revit
Source: illustrated in Revit
VITHAUS x StikBilt
page 30
Special Systems
MODULE I
MODULE II
Hand Winch The winch is used to minimise gap and tighten two adjacent modules. Source: Gorilla
Figure 29. Placing two modules side by side Source: Land to House, 2016
Hand winch is to be installed after the first module is at its final position. The hook is connected to the other module, and before the second module is placed, the winch is turned to drag the second module closer to the first module. Can be operated by one worker
Off-the-shelf loadcertified product
The modules must end at the same point
MODULE V ASSEMBLY
STITCHING & EXTERNAL CLADDING
Module V is placed next to Module II.
Smoothening the connections between modules and installing external cladding at the back part of the house. The cladding at the back of the house is not yet installed because this sides in where the modules meet.
Figure 30. Stitching & External Cladding Source: illustrated in Revit
VITHAUS x StikBilt
page 31
Stitching
Treated connection
The modules have been designed so that their connections are seamless. Most of them happen at the corner of the walls. At these connections, minimal treatment is needed because control joint will be introduced at every corner, especially when there is material changes. The points where two modules meet are shown below.
Control joint
Figure 31. Connection points Source: illustrated in Revit
At the treated connection, compressible material is installed and hand winch will be used to make sure flat and tight connections. Foam sealant is applied along the meeting point from the top to below. It helps to fill the gap and glue both modules together.
STEP 1
STEP 2
STEP 3
STEP 4
Compressible material is installed between modules. Modules are dragged closer using hand winch.
Foam sealant is applied in between to seal the gap and to tighten both modules.
Building paper covers the external wall to ensure water tightness in the building.
Timber wall cladding is installed with battens.
VITHAUS x StikBilt
page 32
3.0
Why KOBEHAUS? Benefits of Prefabrication
KOBEHAUS is using modular prefabrication techniques. The general benefits of modular system are:
30 %
Weight
Materials
30% weight reduction compared to concrete frame (Lawson and Ogden, 2010)
Pre-cut materials in the factory save material usage by 15% (Lawson and Ogden, 2010)
15 %
Quality and Safety
Simpler footing due to the less weight, especially on poor soil (Lawson and Ogden, 2010)
20 %
Higher quality and safety in the factory (Rinas and Girmscheid, 2010)
Costs
Time
Upto 20% saving on the capital costs (Lawson and Ogden, 2010)
50% time reduction compared to traditional construction (Lawson and Ogden, 2010)
50 %
Waste Emissions
70%
Cut the volume of landfill waste by 70% due to the factory manufacturing process (Lawson and Ogden, 2010)
BUILDING MATERIALS RECYCLABILITY AND CONSTRUCTION WASTE RECYCLABILITY (Pons & Wadel, 2011) 50%
45%
40%
35%
Recyclable construction waste
30%
43%
43% of the waste from modular prefabrication is recyclable (Lawson and Ogden, 2010)
25% 20% 10%
10% 5% 1%
Non-prefabricated
VITHAUS x StikBilt
2% Concrete
3% Timber
Steel
Recyclable building materials
page 33
Why KOBEHAUS? Benefits of VITHAUS Being in industry for eighteen years, VITHAUS has been bringing great benefits to clients such as:
Comfort
High quality and low cost
Time effective
VITHAUS manages all the supply, production and assembly processes so that the house is ready-for-use, including the finishing and all necessary equipment
The increase in quality of work and the reduction of cost are enabled by fully prefabricating the modules in the factory.
The design is predetermined and there is no additional time required to conduct tender for builder and subcontractors. Moreover, parallel activities are possible in the factory.
Easy to assemble
Low environmental impact
Opportunity to expand
The modules are lightweight and transportable. Standard truck and trailer are sufficient to transport them. By default, the modules can be assembled on site without crane.
Saving on natural resources and reduction in carbon emission happen at all stages. Timber requires less energy during production. It also absorbs and stores CO2 over its lifetime. Transporting the building in modules reduces the number of vehicles.
The characteristics of the modules makes it practical to be adjusted in the future. A small VITHAUS house can be developed into a larger house or turned into a cozy guest house at anytime.
VITHAUS x StikBilt
page 34
3.1
Why KOBEHAUS? Faster Construction
Due to the prefabrication technique, KOBEHAUS is able to cut the total time by 60% in ideal condition. This time includes the time to prepare the site as well as the time to deliver materials to the site. The reduction in time is calculated through Microsoft Project (Figure 34 and Figure 35 on the next page), and has considered the potential risks through a triangular risk distribution model (Figure 32 and Figure 33 below). Fifty per cent time reduction is realisitic as supported by several studies such as a study by Lawson and Ogden (2010) that says prefabrication can save 50% time according to the degree of prefabrication.
106 days
97.3 days
131.6 days
42 days
37.8 days
50.4 days
Triangular distribution model represents the probability of a scenario by highlighting three important points: the most likely, minimum and maximum conditions. The most likely time for StikBilt and KOBEHAUS are 106 and 42 days, respectively. Figure 32 and Figure 33 show that StikBilt has a bigger standard deviation and a more skewed triangle than KOBEHAUS. In this instance, StikBilt has a bigger possibility to be delayed than KOBEHAUS. The reason is because StikBilt has more unexpected factors on site, including the weather, workers’ availability and productivity, reworks, and health and safety.
Figure 32. StikBilt triangular distribution (above)
Figure 33. KOBEHAUS triangular distribution (below)
Source: illustrated in @Risk
Source: illustrated in @Risk
VITHAUS x StikBilt
page 35
STIKBILT
Start: Wed 10/7/20ID: 0
Finish: Wed 3/3/21 Dur: 106 days Comp: 0%
The network diagrams show that traditional construction technique results in more activities in the critical path. In contrast, modular prefabrication allows parallel manufacturing process, hence, less sequential process with more floating activities can be achieved. KOBEHAUS records a total time of 43 days in comparison to the traditional method at 106 days. Some factors that contribute in the reduction of time are (Larsson and Simonsson, 2012; Construction World, 2019):
Footings installation Start: Wed 10/7/20 ID: 1 Finish: Mon 10/12/20Dur: 4 days Res:
Floor
Start: Wed 10/7/20ID: 2
Finish: Mon 11/9/20Dur: 24 days
Comp: 0% Wall
Start: Tue 11/10/20ID: 8
Finish: Mon 2/8/21 Dur: 65 days Comp: 0% Roof
Start: Mon 12/7/20ID: 20
Finish: Mon 1/18/21Dur: 31 days
Comp: 0%
Window & Door
Start: Tue 1/19/21 ID: 26
Finish: Thu 1/21/21 Dur: 3 days Comp: 0%
Electrical & Plumbing
Start: Mon 10/26/20 ID: 29
Finish: Mon 1/4/21 Dur: 51 days Comp: 0% Fitout
Start: Fri 2/12/21 ID: 32
Finish: Tue 3/2/21 Dur: 13 days Comp: 0%
Finishing & Cleaning Start: Wed 3/3/21 ID: 36 Finish: Wed 3/3/21 Dur: 1 day Res:
Figure 34. StikBilt network diagram Source: illustrated in Microsoft Project KOBEHAUS
Start: 10/7/20
Finish: 12/3/20 Comp: 0%
ID: 0
Dur: 42 days
Page 1
conditioned space, no weather issue
Footings installation Start: Wed 10/7/20 ID: 1 Finish: Thu 10/15/20 Dur: 7 days Res:
Module I
Start: 10/7/20
Finish: 11/18/20 Comp: 0%
A (Terrace)
Start: 10/7/20
Finish: 11/24/20 Comp: 0%
Module II
Start: 10/7/20
Finish: 11/20/20 Comp: 0%
Module III
Start: 10/7/20
Finish: 11/23/20 Comp: 0%
Module IV
Start: 10/7/20
Finish: 11/23/20 Comp: 0%
ID: 2
Dur: 30.5 days
ergonomic leads to higher productivity
ID: 35
Dur: 34.5 days
ID: 39
Dur: 32.5 days
less subcontractordependent
ID: 75
Dur: 33.5 days
ID: 107
less unexpected factors
Dur: 33.5 days
B (Steps & Landing) Start: 11/20/20
Finish: 11/23/20 Comp: 0%
Module V
Start: 10/7/20
Finish: 11/24/20 Comp: 0%
ID: 139
Dur: 1.5 days
ID: 142
Dur: 34.5 days
Finishing & Cleaning Start: Wed 11/25/20ID: 176 Finish: Thu 12/3/20 Dur: 7 days
Figure 35. KOBEHAUS network diagram Source: illustrated in Microsoft Project
simultaneous lines in the factory
better upfront planning can be achieved
Res: Page 1
VITHAUS x StikBilt
StikBilt - Time Schedule ID 0 1 2
Task Name
Duration
STIKBILT
106 days
Floor
4
Material cutting 2 days
5
Beam & joists
7 days
6
Flooring panel
7 days
7
Floor layering for tiling
7 days
Wall
9
Material delivery1 day Material cutting 3 days
11
Wall frame installation
12
Wall insulation 4 days installation
13
Plasterboarding 7 days
14
Building paper 2 days installation
15
Exterior wall
5 days
16
Wall sanding
4 days
17
Exterior wall proofing
3 days
18
Sealing
3 days
Wall painting
7 days
Roof
Material delivery1 day Material cutting 3 days
23
Roof frame installation
24
Roof insulation 3 days installation
25
Ceiling installation 7 days Window & Door
28
November 2020 2 7
12
17
22
27
3 days
Material delivery1 day
28
Window & door 2 days installation
29
Electrical & Plumbing 51 days
30
Under floor 3 days services installation Electrical&Plumbing 7 days rough ins Fitout
13 days
33
Mechanical Electrical installation
34
Joinery&cabinetry 5 days installation
35
Bathroom tub installation
36
23
10 days
27
32
18
31 days
22
31
13
15 days
21
26
8
65 days
10
20
October 2020 3
24 days
Material delivery1 day
19
28
Footings installation4 days
3
8
23
5 days
3 days
Finishing & Cleaning1 day
Project: STIKBILT Date: Tue 10/20/20
Task
Project Summary
Manual Task
Sta
Split
Inactive Task
Duration-only
Fini
Milestone
Inactive Milestone
Manual Summary Rollup
Exte
Summary
Inactive Summary
Manual Summary
Exte
Pag
page 37 December 2020 2 7
art-only
12
17
22
27
January 2021 1 6
11
16
21
26
Deadline
Manual Progress
ish-only
Critical
Slack
ernal Tasks
Critical Split
ernal Milestone
Progress
ge 1
February 2021 31 5
10
15
20
25
March 2021 2
7
KOBEHAUS - Time Schedule ID 0 1 2 3 4 8 19 22 25 28 32 33 34 35 36 37 38 39 40 72 73 74 75 76 104 105 106 107 108 136 137 138 139 140 141 142 143 173 174 175 176
Task Name
Duration
KOBEHAUS
42 days
Footings installation Module I Prefabrication Floor Wall Roof
7 days 30.5 days 29 days 8 days 21 days 13 days
Window & Door Electrical & Plumbing Fitout Cleaning & Finishing Delivery On site assembly A (Terrace) Pre-cut materials Material delivery Construction Module II Prefabrication Delivery On site assembly
18 days 11 days 4 days 1 day 0.5 days 1 day 34.5 days 2 days 1 day 4 days 32.5 days 29 days 0.5 days 1 day
Seaming Module III Prefabrication Delivery On site assembly Seaming Module IV Prefabrication Delivery On site assembly Seaming B (Steps & Landing) Concrete delivery Construction Module V
1 day 33.5 days 21 days 0.5 days 1 day 1 day 33.5 days 19 days 0.5 days 1 day 1 day 1.5 days 0.5 days 1 day 34.5 days
Prefabrication Delivery On site assembly Seaming Finishing & Cleaning
29 days 0.5 days 1 day 1 day 7 days
Project: KOBEHAUS Date: Tue 10/20/20
October 2020 2 4
6
8
10
12
14
16
18
20
22
24
Task
Inactive Task
Manual Summary Rollup
Split
Inactive Milestone
Manual Summary
Milestone
Inactive Summary
Start-only
Summary
Manual Task
Finish-only
Project Summary
Duration-only
External Tasks
Pag
4
ge 1
page 39
26
28
30
November 2020 1 3 5
7
9
11
13
15
External Milestone
Manual Progress
Deadline
Slack
Critical Critical Split Progress
17
19
21
23
25
27
29
December 2020 1 3
5
page 40
3.2
Why KOBEHAUS? Cost Effective
Despite the arguments that prefabrication does not always reduce cost, this section provides cost breakdown that describes how KOBEHAUS will save a total of 13% cost reduction. The time reduction which has been discussed in the previous section is one of the contributors to the cost efficiency. A total of 106 days on site is reduced to 42 days by applying modular prefabrication technique. According to a research by Lawson and Ogden (2016), few factors that affect the saving are:
2-3% 5-7%
3-6%
1-2%
Shorter hiring time
COST SAVING
Professional fees reduction Snagging reduction Site preliminaries
80-89%
11-20% Total cost saving from a typical traditional construction
Cost of modular building
Based on this finding, the 13% cost reduction of KOBEHAUS is proven realistic. Moreover, in the research, Lawson and Ogden (2016) specifies that the proportion of cost in traditional construction will be different to the proportion of cost in modular prefabrication.
11-15%
5-7%
Site Preparations & Preliminaries in traditional construction
Site Preparations & Preliminaries in modular prefabrication
In this research, site preparations and preliminaries include professional fee, site shed and facilities, storage and accommodation, as well as plant and equipment. The reduction from 11-15% to 5-7% implies that modular prefabrication results in the saving on site preparations and preliminaries. On the next page, the cost breakdown of StikBilt and KOBEHAUS is provided. The former has 10.79% site preparations and preliminaries while the latter has 4.82%. A 5.97% saving in site preparations and preliminaries is made by shifting from StikBilt to KOBEHAUS. Indeed, these figures do not lay within the range mentioned by Lawson and Ogden (2016). However, the difference is at the decimal points which is considered negligible.
VITHAUS x StikBilt
page 41
Cost Breakdown Table 06. Cost Breakdown
StikBilt
KOBEHAUS
Site Preparations & Preliminaries Professional Fees 720.00 480.00
Preliminaries 13,252.14 4,417.38
Excavation 4,913.93 2,456.97
Notes
Reduced number of site personnel and external consultants but increased designing fee due to the possibility of changes in modules Reduced cost to tender, reduced time to hire plant, equipment, site shed and facilities, and storage Reduced footings depth and specifications
Construction Concrete in-situ 8,419.52 2,806.51 Concrete formwork 1,238.47 Concrete reinforcement 2,983.79 994.60 Masonry - Brickwork 10,924.65 10,924.65 Carpentry 16,539.33 16,539.33 Structural steel 1,119.51 1,119.51 Insulation 2,442.51 2,442.51 Joinery 15,792.50 15,792.50 Glazing 1,210.15 1,210.15 Hardware 1,107.19 1,107.19 Roofing 9,314.67 9,314.67 Roof plumbing 3,052.70 3,052.70 Windows 8,235.78 8,235.78 Doors 5,379.50 5,379.50 Plastering 12,205.43 12,205.43 Tiling 2,670.18 2,670.18 Paving / Floor coverings 3,702.64 3,702.64 Painting 10,411.77 10,411.77 Plumbing 15,252.52 15,252.52 Drainage 2,341.59 2,341.59 Electrical services 4,038.60 4,038.60 Sundry appliances 1,786.40 1,786.40 Additional charges - -
Reduced in-situ concrete volume No formwork is required Proportional to concrete in-situ Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same Same
TOTAL 159055.47 138,683.07 GST (10%) 15,905.55 13,868.31 TOTAL COST + GST 174,961.02 152,551.38
KOSHAUS saves 13%
Site Prep. & Prelim / Total Cost
10.79%
4.82% VITHAUS x StikBilt
page 42
Initial Capital Costs
$141,140,950 To deliver KOBEHAUS, there are initial costs required. These costs include building a prefabrication factory within Victoria. An estimation of these costs are described below.
Land Acquisition
Working Platforms
$130,000,000
$35,000
This cost is to purchase an approximately 26-hectare vacant land in Truganina, Victoria. The price is estimated based on the listing on Domain (2020).
This cost it to construct all custom-made timber working platforms in the factory. The cost is only an estimate of lump sum amount.
Portal Frames
Steel Equipment
$10,600,000
$50,000
This cost is to construct a portal frame over a total of 10-hectare factory building. The price is estimated based on the rate of building an industrial building using portal frame (Central Steel Build, 2020).
This cost is to provide all custom-made steel equipment in the factory, including the elevated platforms and racking. The cost is only an estimate of lump sum amount.
Gantry Cranes
Trucks
$40,150
$415,800
This cost is to purchase 5x 250kg gantry cranes at $2,500 each and 2x 2000kg gantry cranes at $12,000 each plus GST. The price is derived from a machinery market place in Australia, Machines4u (Machine4u, 2020).
This cost is to purchase 2x 4-axle semi trailers with flatbed at $189,000 each plus GST. The price is derived from a truck market place in Australia, trucksales (trucksales, 2020).
VITHAUS x StikBilt
page 43
Financial Feasibility A total of $141,140,950 is a capital cost that will be spent once at the beginning of the investment. Indeed, it is a significant amount of money. However, 92% of the cost is invested on the land which rather appreciates than depreciates. Based on the previous calculation, KOBEHAUS is able to further reduce the production cost by 13% (refer to the Cost Breakdown). Assuming that StikBilt is normally received 10% profit, selling one KOBEHAUS will generate 23% profit.
10% Assumption on StikBilt’s initial gross profit
+
13% Additional saving by implementing KOBEHAUS
=
23% Total gross profit by implementing KOBEHAUS
Assuming that the selling price is kept the same, with 10% initial gross profit, Selling price Gross Revenue
110% x 174,961.02 23% x $192,457.12
$192,457.12 $44,265.14
80% x $44,265.14
$35,412.11
With 20% running cost, Nett profit
Breakeven point calculation Initial capital cost excl. land
$141,140,950 - $130,000,000
$11,140,950
Breakeven point
$11,140,950 / $35,412.11
314.6 units
Hence, the breakeven point will be achieved at the 315th unit is sold. Referring to the weekly demand index in Victoria (Real Estate Australia, 2020), there is a total of 168.05 demands to buy houses in a week by 10 October 2020. In the last four weeks, there was a total of 557.96 demands of housing. It is not to mention the trend of the graph that is increasing steeply. Kusher also predicts that this number will keep rising following the easing of restrictions in Victoria. Based on this data, we are confident that 315 units can be sold in 24 months (13 units to be sold each month).
168.05 151.38 123.13 115.4
Figure 36. Buyers’ weekly demand index Source: Real Estate Australia, 2020
VITHAUS x StikBilt
page 44
Benefit-Cost Analysis
The factory is expected to have a total of 60-year lifetime with 30 years life of the plant and equipment, and 20-year life of trucks.
Capital Costs Land acquisition
$130,000,000
Working platforms
$35,000
Portal frames
$10,600,000
Steel equipment
$50,000
Gantry cranes
$40,150
Trucks
$415,800
$141,140,950
Replacement Costs Working platforms
$35,000
Steel equipment
$50,000
Gantry cranes
$40,150
Trucks
$2,494,800
Total Costs
$2,619,950 $143,760,900.00
Revenue 315 units / 2 years
$334,644,439.50
Total Revenue
$334,644,439.50
Benefit-Cost Ratio
2.33
Over 60 years, this investment has a projected Benefit to Cost ratio of 2.33. In other words, every dollar invested will generate $2.33 in return. This figure has not considered the land appreciation value over the year. If the value is considered, the benefit-cost ratio will be 5.04 with an assumption of 5% appreciation rate. The land appreciation value is not included in the analysis because it is expected that the business will continue its operation beyond 60 years, hence, there is no plan to sell the land.
VITHAUS x StikBilt
page 45
Barriers KOBEHAUS
4.0
Despite the advantages that have been presented, KOBEHAUS has several limitations: Barrier 1 - In-house workers As KOBEHAUS needs full time workers in the factory, KOBEHAUS needs in-house workers and consultants. Indeed, it results in less dependency to the outsource services. However, it also increases the requirements to take care of the in-house workers. Training, health and safety support, insurances, and other workers allowances are additional aspects we need to consider.
Barrier 2 - Additional designers Referring to the business characteristics, StikBilt must have only a few number of designers either in-house or outsourced. The standard house allows the buyers to make a limited adjustment to their order. However, the size of modules in KOBEHAUS is another variable that designers need to work on.
Barrier 3 - Prefabrication factory To produce KOBEHAUS, an initial investment has to be made to build the factory. This factory requires a significant amount of upfront funding as well as a period of time for the construction. An alternative to this issue is to take senior debt to partially provide the upfront fund.
Barrier 4 - Life Cycle Cost Due to the more investment on assets, implementing KOBEHAUS will incur higher life cycle cost to maintain the assets. Over time, the assets which include the plant and equipment in the factory need replacements. Maintenance and repair fees as well as capital expenditures need to be budgeted. A way to prepare for this issue is by calculating sinking fund and incorporating it in the monthly financial statement. The appreciation of land value can outweigh this expense.
VITHAUS x StikBilt
page 46
Conclusion Report
5.0
Despite its excellence and dominance in Australia’s housing market, StikBilt still implements traditional construction techniques in building its standard house. While the design has been standardised, the fabrication process is not yet standardised. The house is still fully constructed on site. This technique is not only ineffective, it is also inefficient. Constructing the house on site results in a range of dependent aspects that are difficult to control. For instance, weather changes and subcontractors’ availability and quality. An effort given to minimise these aspects will either increase cost or time. This report offers a solution for StikBilt to increase its performance while at the same time reducing time and cost. The proposed solution is to build a partnership with VITHAUS to implement modular prefabrication technique to build StikBilt’s standard house. The modular prefabrication is assessed as the best method to increase effectivity and efficiency in StikBilt’s business. The outcome of modular prefabrication is a modular building, which in this instance is called KOBEHAUS. The technicalities such as the footing requirements, the fabrication in the factory, transportation and the on-site assembly have been described in this proposal. KOBEHAUS shifts the outdoor on-site construction to the indoor factory prefabrication. As a result, it allows for higher quality and more control, and hence increase the productivity and efficiency. The realistic time reduction is at the level of 60% and the cost saving is at 13%. Based on these figures and by reflecting to the current situation, the breakeven point can be achieved in less than six months. Moreover, KOBEHAUS also brings other benefits such as the reduction of weight, material usage and waste emissions. Indeed, there are barriers and limitations in implementing modular prefabrication techniques. However, these barriers can be overcome by proper planning. VITHAUS’s eighteen-year experience in delivering modular building, moreover, is valuable in overcoming these barriers.
“
How can the construction industry become faster, more reliable, more sustainable and safer? All those aspects come together in prefab in modular.”
VITHAUS x StikBilt
page 47
List of Appendices
6.0
Appendix 1: KOBEHAUS Floor Plan Appendix 2: KOBEHAUS North, South Elevations Appendix 3: KOBEHAUS East, West Elevations Appendix 4: KOBEHAUS Sections Appendix 5: Pilot and Escort Guide - VicRoads Appendix 6: Vehicle Configurations - NHVR Appendix 7: Draft Feedback
VITHAUS x StikBilt
page 48
Appendix 1 KOBEHAUS Floor Plan
N PLAN
VITHAUS x StikBilt
page 49
Appendix 2 KOBEHAUS North, South Elevations
NORTH ELEVATION
SOUTH ELEVATION
VITHAUS x StikBilt
page 50
Appendix 3 KOBEHAUS East, West Elevations
EAST ELEVATION
WEST ELEVATION
VITHAUS x StikBilt
page 51
Appendix 4 KOBEHAUS Sections A
B
B A
SECTION A
SECTION B
VITHAUS x StikBilt
page 52
Appendix 5 Pilot Escort Guide - VicRoads Pilot and Escort Graph Guide Over 6m wide or 60m long - a combination of certified pilots and/or VicRoads escort vehicles will be required 6.0 5.51
3 Certified Pilots
5.5
5.0
2 Certified Pilots*
4.51
4.5
4.0
Width In Metres
1 Pilot
3.51
3.5
3.0
No Pilot or Escort 1 Pilot
2.5
Overall Length of Vehicle and Load in Metres
26 26.01
3 Certified Pilots
2 Certified Pilots* 30 30.01
35 35.01
NOTE: * When travelling on a freeway outside the Melbourne and Geelong Urban Areas, only one (1) Certified Pilot Vehicle is required Note: - Number of pilot/escort vehicles required may depend on variable circumstances and will be considered on a case by case basis.
This guide does not apply to mountainous areas
VITHAUS x StikBilt
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Appendix 6 Vehicle Configurations - NHVR National Heavy Vehicle Regulator
Common Heavy Freight Vehicle Configurations
Disclaimer: This diagram shows some of the common heavy vehicle combinations used in Australia. Access for some illustrated vehicles and configuration is subject to an access authorisation (notice or permit). Other heavy vehicle configurations may not be represented. The mass and length limits shown are from the Heavy Vehicle (Mass, Dimension and Loading) National Regulation (the MDL Regulation) and are provided for general guidance only. These limits are available only to vehicles that comply with all other regulatory requirements (e.g. width and height limits, tyre width, vehicle standards, load restraint, suspension type etc). In some circumstances, access may be considered under a different vehicle class or other mass concessions and length limits may also be available. The NHVR website provides links to the MDL Regulation and to national and state Notices which may apply, depending on individual circumstances. For further information, contact the NHVR at 1300 MYNHVR (1300 696 487) or info@nhvr.gov.au or www.nhvr.gov.au/contact-us
Description
Maximum Length (metres)
Maximum Regulatory Mass under GML (tonnes)
Maximum Regulatory Mass under CML (tonnes)
Maximum Regulatory Mass under HML (tonnes)
2 Axle Rigid Truck
≤ 12.5
15.0
CML does not apply
-
3 Axle Rigid Truck
≤ 12.5
22.5
23.0
-
4 Axle Rigid Truck
≤ 12.5
26.0
27.0
-
4 Axle Twinsteer Rigid Truck
≤ 12.5
26.5
27.0
-
5 Axle Twinsteer Rigid Truck
≤ 12.5
30.0
31.0
-
3 Axle Semitrailer
≤ 19.0
24.0
-
-
4 Axle Semitrailer
≤ 19.0
31.5
32.0
32.0
5 Axle Semitrailer
≤ 19.0
35.0
36.0
37.5
5 Axle Semitrailer
≤ 19.0
39.0
40.0
40.0
6 Axle Semitrailer
≤ 19.0
42.5
43.5
45.5
1. COMMON RIGID TRUCKS - GENERAL ACCESS (a)
6.0t
(b)
9.0t
6.0t
(c)
16.5t
6.0
(d)
20.0t
10.0t*
(e)
10.0t*
16.5t
20.0t
2. COMMON SEMITRAILER COMBINATIONS - GENERAL ACCESS (a) 6.0t
9.0t
9.0t
(b) 6.0t
9.0t
16.5t
(c) 6.0t
9.0t
20t
(d) 6.0t
16.5t
16.5t
(e) 6.0t
16.5t
20.0t
3. COMMON RIGID TRUCK AND TRAILER COMBINATIONS (General access when complying with prescribed mass and dimension requirements) (a)
6.0t
(b)
9.0t
6.0t
(c)
9.0t
6.0t
(d)
6.0t
(e)
6.0t
(f)
16.5t
6.0t
(g)
16.5t
6.0t
(h)
16.5t
10.0t*
(i)
15.0t
16.5t
16.5t
16.5t
10.0t
16.5t
*
4. COMMON B-DOUBLE COMBINATIONS - CLASS 2
9.0t** 9.0t**
9.0t 9.0t
15.0t
9.0t** 16.5t**
18.0t
16.5t** 16.5t**
9.0t 16.5t
16.5t
**
16.5t
**
(a) 6.0t
16.5t
16.5t
16.5t
20.0t
16.5t
16.5t
20.0t
(c) 6.0t
16.5t
(d) 6.0t
16.5t
5. COMMON TYPE 1 ROAD TRAINS - CLASS 2
20.0t
20.0t
16.5t
16.5t
16.5t
20.0t
(a) 6.0t
16.5t
16.5t
(b) 6.0t
16.5t
20.0t
(c) 6.0t
16.5t
20.0t
20.0t
16.5t
20.0t
20.0t
16.5t
20.0t
20.0t
20.0t
(f) 6.0t
16.5t
20.0t
16.5t
20.0t
20.0t
6.0t
16.5t
20.0t
20.0t
20.0t
20.0t
(g) (h)
6.0t
16.5t
16.5t
6. COMMON TYPE 2 ROAD TRAINS - CLASS 2
16.5t
16.5t
16.5t
(a) 6.0t
16.5t
20.0t
16.5t
20.0t
16.5t
16.5t
20.0t
20.0t
20.0t
20.0t
6.0t
16.5t
20.0t
6.0t
20.0t
16.5t
20.0t
16.5t
20.0t
16.5t
20.0t
20.0t
16.5t
20.0t
16.5t 20.0t
16.5t
6.0t
16.5t
20.0t
20.0t
20.0t
20.0t
20.0t
20.0t
20.0t
20.0t
(g) 20.0t
16.5t
(h) 6.0t
16.5t
20.0t
20.0t
20.0t
20.0t
40.5
41.0
-
3 Axle Truck and 2 Axle Pig Trailer
≤ 19.0
37.5
CML does not apply
-
3 Axle Truck and 3 Axle Dog Trailer
≤ 19.0
42.5
43.5
-
3 Axle Truck and 3 Axle Pig Trailer
≤ 19.0
40.5
CML does not apply
-
3 Axle Truck and 4 Axle Dog Trailer
≤ 19.0
42.5
43.5
-
4 Axle Truck and 3 Axle Dog Trailer
≤ 19.0
42.5
43.5
-
4 Axle Truck and 4 Axle Dog Trailer
≤ 19.0
42.5
43.5
-
7 Axle B-double
≤ 19.0
55.5
57.0
57.0
8 Axle B-double
≤ 26.0
59.0
61.0
62.5
8 Axle B-double
≤ 26.0
59.0
61.0
62.5
9 Axle B-double
≤ 26.0
62.5
64.5
68.0
9 Axle A-double
≤ 36.5
72.0
74.0
74.0
11 Axle A-double
≤ 36.5
79.0
81.0
85.0
12 Axle A-double
≤ 36.5
82.5
84.5
90.5
12 Axle Modular B-triple
≤ 35.0
82.5
84.5
90.5
12 Axle B-triple
≤ 36.5
82.5
84.5
90.5
14 Axle AB-triple
≤ 36.5
99.0
101.0
107.5
15 Axle AB-triple
≤ 36.5
102.5
104.5
113.0
11 Axle Rigid Truck and 2 Dog Trailers
≤ 36.5
88.5
90.5
91.0
16 Axle A-triple
≤ 53.5
115.5
117.5
124.5
18 Axle A-triple
≤ 53.5
122.5
124.5
135.5
15 Axle AB-triple
≤ 44.0 – Classified by the NHVR as Type 1 when L ≤ 36.5m
102.5
104.5
113.0
13 Axle Rigid Truck and 2 Dog Trailers
≤ 47.5 – Classified by the NHVR as Type 1 when L ≤ 36.5m
95.5
97.5
102.0
17 Axle BAB-Quad
≤ 53.5
119.0
121.0
130.0
18 Axle BAB-Quad
≤ 53.5
122.5
124.5
135.5
17 Axle ABB-Quad
≤ 53.5
119.0
121.0
130.0
18 Axle ABB-Quad
≤ 53.5
122.5
124.5
135.5
20.0t
(f) 6.0t
≤ 19.0
20.0t
(e) 6.0t
-
3 Axle Truck and 2 Axle Dog Trailer
20.0t
(c) (d)
-
CML does not apply
20.0t
(b) 6.0t
-
30.0
20.0t
(e) 6.0t
30.0
≤ 19.0
20.0t
(d) 6.0t
≤ 19.0
2 Axle Truck and 2 Axle Pig Trailer
16.5t
(b) 6.0t
2 Axle Truck and 2 Axle Dog Trailer
20.0t
Add one tonne if twinsteer axle group is load sharing.**The mass of a dog trailer shall not exceed the mass of the towing vehicle under Schedule 1, Part 1, section 2(4) of the Heavy Vehicle (Mass, Dimension and Loading) National Regulation. Please note, additional limits are allowed for steer axles under Schedule 1, Part 2 of the Heavy Vehicle (Mass, Dimension and Loading) National Regulation. © Copyright National Heavy Vehicle Regulator 2019, creativecommons.org/licenses/by-sa/3.0/au
*
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Appendix 7 Draft Feedback Structure Table of Contents entry in Table of Contents
v
Background is not part of Introduction
v
Missing citations
v
Caption on images
v
Missing quantified benefits
v
Missing Conclusion
v
Formatting Cover page, table of contents,
v
Font style, headings and sub-headings (preferably numbered)
v
Paragraph justification
v
Appropriate use of captions and annotation in figures, charts and tables
v
High-resolution images with proper captions and annotations
v
Contents Technical drawings: plans, elevations, sections
Appendix 1 - Appendix 4
Member schedules and choice of materials
section 1.0 Proposed Technique
Joints and connections
section 2.1 Prefabrication in Factory
Performance and efficiency diagrams
section 3.0 Why KOBEHAUS?
Assembly charts
section 3.1 Time effective
Production procedures
section 2.1 Prefabrication in Factory
Transportation packing
section 2.3 Transportation
Installation process
section 2.4 On-site Assembly
Benefits
section 3.0 Why KOBEHAUS?
Limitations and solutions
section 4.0 Barriers
Cost-benefit analysis table
section 3.2 Cost Effective
One key area of improvement in the building in full details using proper forms of communication.
section 3.0 Why KOBEHAUS?
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References
7.0
Build, C. S. (2020). Shed Cost Per Square Metre. Retrieved from https://www.centralbuild.com.au/shedcost-per-square-metre/ Domain. (2020). 1241 Vacant Lands for sale in Truganina, VIC, 3029. Retrieved from https://www.domain.com. au/sale/truganina-vic-3029/vacant-land/?sort=price-desc Girmscheid, T. R. a. G. (2010). Business Model: The Cooperative Production Network That Enables Mass Customized Production Methods in the Swiss Precast Concrete Industry. Paper presented at the 18th CIB World Building Congress, Salford, United Kingdom. http://site.cibworld.nl/dl/publications/tg57_pub354. pdf#page=43 Glenn. (2018, 3 May 2018). The 50 largest cities and towns in Australia, by population | 2018 update. Retrieved from https://blog.id.com.au/2018/population/population-trends/the-50-largest-cities-and-towns-inaustralia-by-population-2018-update/ Hofstede. (2020, 2020). Compare Countries. Retrieved from https://www.hofstede-insights.com/product/ compare-countries/ Homes, Q. (Producer). (2019, 21 September 2020). Tour Our Quality Homes Factory Building Process. [Video] Retrieved from https://www.youtube.com/watch?v=Kg8_yagUBo4 Klopp, P. (Producer). (2016, 16 October). Modular Home Delivered and Set Up. Retrieved from https://www. youtube.com/watch?v=JVcvCWY14XY Kusher, C. (2020, 14 October 2020). October 14 REA Insights Weekly Property Demand Report, 2020. Retrieved from https://www.realestate.com.au/insights/october-14-rea-insights-weekly-property-demandreport-2020/ LandtoHouse (Producer). (2016, 15 October). Set the House on the Foundation - Modular Home #35. Retrieved from https://www.youtube.com/watch?v=KPXsTuz39aw Machines4u. (2020). Retrieved from https://www.machines4u.com.au/browse/construction-equipment/ crane-296/gantry-crane-839/ ModularTransportCanada (Producer). (2016, 17 October). Modular Transport Canada Delivers a house in the woods. [Video] Retrieved from https://www.youtube.com/watch?v=Gc4O-5l5c3s&list=TLPQMDkxMDIwMj BtvKtxgCVLNw&index=2 NHVR. (2019). Common Heavy Freight Vehicle Configurations. Ogden, R. M. L. a. R. G. (2010). Sustainability and Process Benefits of Modular Construction Paper presented at the 18th CIB World Building Congress, Salford, United Kingdom. http://site.cibworld.nl/dl/publications/ tg57_pub354.pdf#page=43 R., A. (2020, 24 April 2020). The Journey Home: All About Manufactured Home Foundations. Simonsson, J. L. a. P. (2012). DECREASING COMPLEXITY OF THE ON-SITE CONSTRUCTION PROCESS USING PREFABRICATION: A CASE STUDY. Paper presented at the 20th Annual Conference of the International Group for Lean Construction. https://iglcstorage.blob.core.windows.net/papers/attachment-7a5f023b4d30-4576-8d66-5aa3f0cb8de1.pdf trucksales. (2020). 2,634 Trailers for sale in Australia. Retrieved from https://www.trucksales.com.au/ items/trailers-category/ VicRoads. (2020). Pilot and Escort Graph Guide. Retrieved from Australia: Victoria, S. G. o. (2020, 2020). Victoria’s restriction levels. Retrieved from https://www.dhhs.vic.gov.au/ victorias-restriction-levels-covid-19 VITHAUS, S. (2020, 2020). Prefabricated Homes - design, manufacture, sale. Retrieved from https://vithaus. eu/ VITHAUS x StikBilt