6 minute read
Powering Offsite with Digital Technology
Richard Hipkiss, Development Director for the Modular and Portable Building Association (MPBA), discusses the role digital technology plays as offsite construction rapidly becomes a preferred delivery model.
The government and the wider public sector play a pivotal role in encouraging and facilitating the uptake of modern methods of construction (MMC). Progressive building systems that deliver at scale and increase productivity are now in great demand. Historically, manufacturing operations have been considered extensions to construction processes instead of an integral and important part. This perception is changing. As offsite construction becomes an increasingly dominant force that utilises high levels of technology, the lines between manufacturing, engineering and construction have become blurred – creating a need for new skills and redefining existing ones.
Positive impact
Volumetric modular technology offers benefits that have a huge positive impact on the construction industry, bringing longstanding traditional practices up to date. The first key shift away from traditional methods is that build processes take place in controlled factory conditions. The farreaching implications of this require a change of mind-set and approach. At the core of volumetric modular production, Design for Manufacture and Assembly (DfMA) protocols and Building Information Modelling (BIM) enable optimal configuration of offsite solutions by connecting multi-discipline and multi-tier teams right from the beginning of the design development process.
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DfMA facilitates early design detail and three-dimensional design information, while BIM minimises the risk of errors by eliminating the time-consuming process of translating engineers’ information into cutting lists and assembly drawings. BIM also enables the optimising and testing of designs in virtual and pre-production environments.
Technology is ever evolving, and the volumetric industry is now integrating BIM and digital design specifications with Enterprise Resource Planning (ERP) and Material Requirement Planning (MRP). This technology permits manufacturing simulation and visualisation, clash detection and virtual onsite assembly modelling, which can be enhanced using augmented and virtual reality.
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Digital technology is as relevant to the offsite manufacturing process as it is to design and architecture.
Gaining considerable momentum
Offsite technology encompasses a variety of panelised and volumetric methods of construction. At the forefront of offsite techniques, volumetric manufactured buildings have a remarkable impact on reducing costs while increasing quality and safety measures. Having gained considerable momentum over the past few years, modular construction makes up 60-70% of offsite techniques and reduces build times by an impressive 50-60%.
Module selection is influenced by transportation dimensions and shipping distances. A number of other factors are also holistically considered to achieve optimal design efficiency. Connection details for example together with specific site logistics such as foundation/transfer deck requirements, installation and crane costs.
The demand for customisation has led the manufacturing industry to develop methods for adaptation during mass production while meeting specific customer needs. Each individual material can be selected specifically for its performance characteristics, tailoring every inch of a modular build. Eco-friendly materials are often specified, and waste is recycled or reused. As units are factory manufactured, stringent quality control processes can be undertaken within these well-managed environments. These in-house conditions also prevent weather from inhibiting the manufacturing process, guaranteeing efficiency. On top of this, modular construction enables site work and building processes to be completed simultaneously, reducing labour costs and build times.
Repeatable quality and safety
Volumetric modular practices augment the construction industry with a multitude of benefits that span from greener, healthier environments to maximised sustainability, heavily reduced costs and quick build times. With modular construction all data can be validated and co-ordinated as part of a structured process, which helps provide accurate and reliable information for clients at the point of handover. It also means it is easier to identify what products and material specifications were used on previous projects should any legislation changes occur.
By verifying the materials and products to be used on a construction scheme and by simplifying the onsite assembly process, volumetric modular construction offers developers an opportunity to avoid many traceability issues. Modular construction helps ensure client satisfaction and product assurances through the certainty and quality embedded into the build process. With its powerful combination of controlled deliverables and customisable outputs, modular construction provides the repeatable quality and safety needed to meet client demands.
Education and training
As the construction industry starts to emerge from this pandemic, it is important we lay the foundations for a more rapid and sustainable building programmes, where the focus is on quality and delivering buildings that are fit for the future. To assist the MPBA has launched a new Training Centre delivering education programmes where young and mature students can learn key skills relevant to the industry.
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The facility – located in Coventry, West Midlands – offers a comfortable environment for industry experts to share valuable knowledge away from the pressures of the workplace. The Training Centre provides the MPBA with the ability to deliver a consistent high level of informative technical and best practice programmes for members.
For more information visit:
www.mpba.biz
Images:
01. Volumetric modular development at
Desborough Road. Courtesy Premier Modular 02. BIM modelling is paramount to offsite precision. Courtesy McAvoy Group 03. Modular factories produce quality and predictable outputs. Courtesy Wernick
Buildings
ITW Construction Products Offsite, using their proven method of Customer-Back Innovation and listening to market challenges, have created a brand new industry solution – Gang-Nail Truss Frame*.
Known as the innovative alternative to traditional timber frame walls, Gang-Nail Truss Frame recently won the ‘Best Brand New Product’ in the Housebuilder Product Awards 2022. This new solution is a system of standardised wall elements made offsite, that combine into larger modules on-site. The Gang-Nail Truss Frame wall elements are made up of timbers pressed together at the joints using Gang-Nail nail plates. This new solution has been in development for over two years and addresses many market challenges including:
Shortages and Cost of OSB
Gang-Nail Truss Frame gains its structural strength and superior resistance to wind-loading from the
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design and the use of Gang-Nail nail plates for the joints of the timbers. This eliminates the need for OSB, currently used to provide structural integrity to traditional timber frame walls. This means the elimination of panel nailing and OSB, and the associated use of synthetic resins and waxes.
U-values
The Gang-Nail Truss Frame structure allows a lesser amount of insulation to be wrapped around the wall panel’s external face, eliminating thermal bridges and saving on material. U-values of 0.18 W/m²K and lower are easily achievable, meeting new Part-L standards.
The Shift Towards Offsite Manufacturing
The Gang-Nail Truss Frame wall elements are designed to be made offsite, meaning they can be manufactured in a controlled environment. This helps meet the government’s pre-manufactured value (PMV) threshold of 55% for the Affordable Homes Programme.
Efficiencies in Manufacturing
Since the Gang-Nail truss Frame wall elements are made offsite in a controlled environment where the process of making the panels is the same every time, efficient manufacturing is pretty much guaranteed. With the elimination of cutting and nailing of OSB, potential bottlenecks in the production process are removed. The need for double sheathing is eliminated and safety is enhanced as there is no possibility of nails hitting nails.
Complexity in Design Calculations
Gang-Nail Truss Frame structural elements have pre-defined values based on external testing of the panels. This means building designers can rely on the published values all the way through from design to onsite construction. This also simplifies calculations in case of re-design, saving time and reducing complexity. *Patent Pending
To find out more about ITW Construction Products Offsite’s innovative Gang-Nail Truss Frame solution please email: technical@itwcp.com
Images:
01. Gang-Nail Truss Frame gains its structural strength and superior resistance to wind-loading from the design and the use of Gang-Nail nail plates for the joints of the timbers
