Welcome to

1
Welcome to Overview of the Offsite Industry
Presented by Bryan Woodley Senior Consultant
Mtech Group
2
Mtech Group Overview
Specialist Offsite Construction (OSC)
Consultancy Independent company formed in
1996 Focus on the development application OSC
technology Range of specialist skills
include New product development New product
evaluation testing Supply chain development
management New technology selection
implementation Construction project management
3
Offsite construction in UK the history
Modern history - Offsite has been in use for
over 35 (80) years Significant growth last 10
years (not just because of Mtech!)
so what has prompted this ?
New government in 1996 with major
infrastructure promises Recognised need to
improve construction efficiency Fear of skills
shortages Concern over tender price inflation
4
Incentives for Change

• Government initiatives Government pressure
  (DfES, P21, Education)
• Client expectation - better quality, faster
  at less cost
• Skilled labour issues reducing labour force
  with increasing costs
• Increased focus - Health Safety increased
  litigation
• Sustainability issues reduce energy
  consumption
• Growing acceptance - innovative construction
  methods
• Building Regulations difficult to achieve with
  traditional construction
• Code for Sustainable Homes only MMC solutions
  available at levels 5 6

innovative industry rapid change
5
What is MMC?
It is more about process than product!
6
Terminology and Definitions
Modern Methods of Construction/ Offsite
Construction Prefabrication Pre-assembly are
commonly combined under the titles Modern Methods
of Construction MMC/ OSCOffsite Construction
eliminate prefab stigma
7
Terminology and Definitions
Offsite Construction Offsite Construction
includes all those elements of construction that
involve the pre-assembly (joining together or
prefabrication) of a number of construction
components, which would otherwise be
traditionally incorporated in the works as
separate components.
8
Terminology and Definitions
Volumetric buildings Pre-engineered factory
manufactured 3-Dimensional elements of a building
normally including superstructure, cladding
finishes and internal fit-out regularly
referred to a modular buildings. Adjacent
modules are joined together on site to form
complete multi-storey buildings of almost any
size or configuration.
9
Terminology and Definitions
Panellised buildings Buildings constructed from
factory manufactured planar elements (walls,
floor increasingly roof panels) to form the
complete building superstructure. The panels can
be typically timber frame, light steel frame or
pre-cast concrete. Fit-out cladding finishes
are finished traditionally on site
10
Terminology and Definitions
Pod construction Factory manufactured
3-Dimensional elements of building that can be
incorporated into the main building
superstructure on site. Typically this method of
construction includes bathroom kitchen pods
which are fully finished internally and are
delivered to site as the building is erected to
increase the speed of build of the intensive
areas of the construction
11
Terminology and Definitions
Standardisation Standardisation is the widespread
and systematic use of processes and components
with repeated regularity in construction and
engineering projects with the conscious objective
of achieving optimum economy, quality and
functionality
12
Fast-Track Foundation System Technology
Innovative foundation systems are establishing a
presence in UK Construction Industry.
Requirements for more construction on Brownfield
sites has been the catalyst for new methods of
creating foundation structures that reduce the
amount of ground disturbance required.
Photographs courtesy of Van Elle Roger
Bullivant.
13
Timber Frame Construction Open Panel
Timber frame technology is a well established
construction method in both the private and
social housing sectors. There is a strong
manufacturing base providing a range of technical
solutions to suit varying construction needs.
Photographs courtesy of Torwood, Fillcrete,
Willmott Dixon Space4.
14
Timber Frame Construction Closed Panel
This advanced method of constructing using timber
frame provides a more completed solution. The
panel is insulated and closed in the factory and
can often include conduits for services / plug in
services as well as windows and doors.
Photographs courtesy of TRADIS Space4.
15
Structural Insulated Panel System Construction
Although a well-established method of
construction in Japan US since the 1960s, SIP
technology has only recently emerged in the UK.
Consequently, the manufacturing base is a
relatively immature and supply volumes are still
comparatively small.
Photographs courtesy of Marshalls Panablok,
TEKhaus, Space4 SIPtec.
16
Light Gauge Steel Frame Construction
LGSF technology is now well established in the
UK Construction Industry. Since the technology
emerged in the early 1990s, led by the Corus
Surebuild system, a number of new LGSF
derivatives have been developed. The
manufacturing base for this technology is
expanding rapidly.
Photographs courtesy of Corus Framing, Fusion, WA
Browne Willmott Dixon.
17
Concrete Panel Tunnel Form Construction
Concrete technology is well established in the UK
Construction Industry. The use of concrete for
fast-track construction methods has generated a
variety of innovations using this well trusted
material. Manufacturers are responding to market
demands for new methods of application for this
technology.
Photographs courtesy of Structherm, ThermoneX,
SHG, Milbank Industries HH Celcon.
18
Volumetric Buildings Construction
Although a well-established technology, the
application of volumetric modular construction
has only recently been accepted as a viable
method of permanent construction. Leading system
building manufacturers have taken steps to
develop suitable products for the UK Construction
Industry.
Photographs courtesy of Yorkon, Britspace, Banro,
Kajima, Meteor Systems, Hanson TiS Sunley Plc.
19
Mechanical Electrical services
Manufacturers such as Crown House and NG Bailey
are focusing on the pre-fabrication of large
elements of the services within buildings to
develop their new products. Minimising on site
activities and working in confined spaces are key
drivers in this area.
Photographs courtesy of NG Bailey, Crown House
Laing ORourke.
Improved working knowledge improves working
performance
20
Bathroom Kitchen Pod Technology
Bathroom and kitchen pods are currently one of
the more advancing market sectors within MMC.
With pods being constructed from Timber, Light
Gauge Steel and GRP the choice is far greater.
Structural pods are adding a new dimension to the
building process.
Photographs courtesy of Gateway, Polybeam Paul
Bonarcorsi.
Improved working knowledge improves working
performance
21
Fast-Track Cladding System Technology
The past two years have seen the emergence of a
large number of fast-track cladding systems
ranging from component-based thin brick systems
to large panel terracotta and render systems.
External insulated and rain screen cladding
systems have become acceptable forms of cladding.
Photographs courtesy of Taylor Maxwell, Powerwall
Systems.
22
Panellised Roof System Technology
Innovation in roofing applications has yet to
establish a strong foothold in UK Construction
Industry. The cost competitive methods of
creating a traditional roof structure i.e. truss
rafters, means that innovative solutions
currently struggle to be commercially viable
unless a room in the roof is required.
Photographs courtesy of TEKhaus, Milbank
Industries, Vencel Resil Wards.
23
Other offsite techniques
Staircases and lift shaft modules Modular
wiring integrated services Internal
partitioning internal fit-out Balconies and
parapets Micro prefabrication . . .
. . . and many more
24
Impact on labour costs
Recent Procure 21 project - Lighting Power
Installation value 750,000

• Actual savings on the project were -
• 10 saving on estimated cost 75,000
• 6-8 week reduction to 1st fix program.

25
UK offsite output 2006
total 1.5b to 2.0b 2006
growth 15 to 30 per annum
26
Evaluating Offsite Construction

• It is essential to implement a project-wide
  strategy
• A balance must be found for the
  time/cost/quality relationship
• Consider product performance durability
  product certification
• Assess compliance with Building Regulations
• Implement training programme - project
  management skills
• Review design issues - dimensional
  co-ordination tolerances
• Consider the degree of innovation - Project
  Risk Strategy
• Develop targets and milestones use of KPIs
  and benchmarking

27
Standardisation Customisation
28
Product Design-life Considerations
Permanent structures (60years ) lender
issues Considerable development in materials
and technology Re-interpretation of Building
Regulations Statutory Approvals Regulatory
requirements Council of Mortgage lenders
Approvals Third Party Accreditation BBA or
BRE Certification Zurich Warranty LANTAC
Type/ System or Product Approvals Independent
validation UKAS Approvals
29
Benefits of offsite?
faster construction process improved value
for money overcome pending skills shortage
reduce site disruption greater certainty and
predictability better quality exemplar Health
and Safety demonstrable sustainability lower
capital and WLC
30
Key challenges for offsite
instigate specialist skills training for
all mobilise integrate the whole supply
chain ruthless standardisation overcome the
limiting volumecost equation prove the cost
business case demonstrate offsites
sustainability credentials revolutionise
existing procurement methods need to set clear
targets measure!
31
the opportunities for offsite
grow diversity capability of offsite
systems develop UK manufacturing base
expertise encourage client leadership exploit
the new momentum industrialise the
construction process make offsite mainstream!
32
In Conclusion
The advantages offered by the various forms of
MMC technology are too significant to be
ignored MMC technology is not the panacea to
solve all construction ills, but if an innovative
strategy is consistently applied throughout the
project process, along with best practice project
management techniques, major benefits will be
realised
33
Thank you for listening
we look forward to working with you.