Off-Site Wood Construction:

Transcription

1 Off-Site Wood Construction: What, Why, How and the Future. Randall S. Walter, AIA, LEED AP Disclaimer: This presentation was developed by a third party and is not funded by WoodWorks or the Softwood Lumber Board.

2 The Wood Products Council is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES), Provider #G516. Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. Certificates of Completion for both AIA members and non-aia members are available upon request. This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

3 Course Description Due to skilled labor shortages, compressed schedules, and the potential for greater quality control, off-site wood construction has become increasingly popular. This presentation will cover the unique design and construction techniques associated with pre-fabricated and off-site panelized wood systems. An introduction to the different levels of off-site construction and review of associated products and services will be followed by a demonstration of cost and schedule benefits based on real-world projects. A step-by-step process will be presented for designers new to off-site construction, with information on how to find and utilize partners and resources, the integrated design process, and differences compared to traditional on-site methods. Trends and future projections for the use of off-site construction, as well as its advantages, will also be reviewed.

4 Learning Objectives Discuss factors such as skilled labor shortages and potential for greater quality control that have prompted the increased use of off-site wood construction. Using commercial and multi-family case studies, review the cost and schedule savings realized through the use of off-site wood construction. Highlight design and construction techniques unique to off-site construction such as assembly selection, sequencing and parallel construction. Demonstrate the tools available to design and construction professionals looking to implement off-site construction, such as design resources, partners and industry associations, and 3D modeling methods.

5 Credit(s) Earned Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. certificates of Completion for both AIA members and non-aia members are available upon request. This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or constructed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specfic materials, methods, and services will be addressed at the conclusion of this presentation.

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7 Big breakthroughs happen when what is suddenly possible meets what is desperately necessary. -Thomas Friedman

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9 An Industry Unaffected by Other Technology

10 A Challanged History Built-in inefficiency Weather-based delays, shutdowns Linear Process Raw materials to finished product under difficult conditions, with inadequate tools Skill degradation Extreme personnel turnover rates (20%-60%) Majority of workers have minimal education Lack of education, skills & attitude for new demands Minimal or zero requirements Poor quality Most defective products consumers purchase.. 15% - 80% serious defect rate Decades long industry culture of accepted compromise

11 For $20, miles an hour Fuel efficient engine 200,000 + miles w/ little maintenance Battery powered electrical system Multiple computers & sensors Auto Heating & Cooling Complete sound system Comfortable Seats w/ power controls Airbag protection Defects unacceptable

12 For $20,000 Just sits there Walls & Roof Lights & outlets Defects accepted

13 Off-Site Opportunity Precise 1/32 tolerances (thickness of a business card) Consistent Quality Industrial manufacturing process instead of in-situ (on site) Equivalent of ISO9001 type assurance Lean Manufacturing Ideal work space Repetition Develop Sub Assemblies Added value through integration Packaging waste control Continuous Improvement Interface Control Feed Back Loop

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15 Other Reading Prefab Architecture by Ryan Smith Refabricating Architecture by Steven Kieran and James Timberlake

16 Other Industries Get It

17 Would You Build a Car in Your Driveway?

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19 Off site/prefab opportunity: area of expansion Modular: reasonably well defined industry Constrained design

20 Value Proposition On-Site Easily disrupted by weather Challanging safety environment Handling challanges Theft Off-Site Compressed schedule Lean manfacturing Waste control Better jobs

21 Intersection of Strategies Virtual Building Design Build Deliver Digital Fabrication Offsite BIM Prefab Kits, panelization, modules Montage site for assembly Reduced site impact time, waste CNC IPD Precision TEAM = 3D printed buildings

22 Open-Built & Montage Principles and Innovations for 21 st Century Homebuilding

23 Built From Model: Parrallel Processing Foundation Shell Modeling Fabricate Install Mech Connections Exterior Finishes Millwork & Products Modeling Fabricate Install Site Construction Layout from plans, cut, attach, measure, order, wait, install, measure, cut, fit,

24 Learn from Everywhere Scandinavia Optimization Most Off-Site Construction Appropriate Technology Best Energy Standard Building Science Montage Design New England TF Legacy Building Off-site benefits and skills 3D modeling value Discipline of connections Site efficiency tools & logistics Discipline & Skills Japan Lean Manufacturing Kaizen Precision Power of Modularity Tradition of Perfection Germany/Austria/Switzerland CNC Tools Software Lead Technology Adaptation Modern Manufacturing Advanced Education for trades Durable Building standard Montage Holland Open Building Lives must Prevail Rational Design & Building Time based organization Sustainability through Adaptability Dimensional Coordination France Pride in Craft/training Craft knowledge Personal discipline Humility Historical Perspective

25 Montage Design & Building Montage - Any combination of disparate elements that forms or is felt to form a unified whole. Montage is about prefabrication and assembly... the dual nature is identified by the dichotomy between montage as a construction strategy and montage as a aesthetic strategy....a way of thinking about architecture as an instrument rather than a monument.. - Charlotte Bundgaard, Montage Revisted

26 Montage Building Site for assembly only; avoid cutting and shaping. Site is the worst place to attempt to control Quality Efficiency Cost Time Job satisfaction

27 Open-Built Strategy 50,000 to 50 (Distilling Parts and Pieces into high value Building Elements)

28 Building Element Fabrication A continuum of change

29 Build it Twice: Virtual before Actual BIM to BPM

30 Everything Modeled: Plan, Deliver and LEAD Power of BIM Design = Simulated building Automated PM information costs, supply chain, shipping, etc. Automated cutting and shaping machine code

31 BIM to CNC Our Tireless Workers

32 Flat Pack Virtual and Actual Shipping Recycled Wrapping

33 Gantry System: Wall Production

34 Site Montage

35 Site Assembly

36 Mechanical Cartridges

37 Cartridge Installation

38 Core-Wall Integrated Mechanical System Element

39 Core-Wall Installation

40 Bath and Mechanical Room Pod

41 Mechanical Room Module

42 Bathroom Pods Montage

43 Additional Strategies: Open Building z How Buildings Learn by Stewart Brand Supports by John Habraken

44 Disentangle the Process Shell Impact: Public control, regulation Intent: Long term durability, sustainability Players: Architects, Engineers, Public Agencies Infill Impact: Private, freedom Intent: Easy change, modification Players: Inhabitants, interior designers, semi-professionals.

45 Open Building Disentanglement

46 Montage Design: Dimensional Coordination

47 OBGrid 3D Matrix Structure 2 ft. 2 ft. x 4ft. Infill: 3 in. 6 in. x 1 ft. Vertical: 7.5 in. Divisibles Multiples

48 Montage Design Design Assemblies, Compose Designs

49 Mass Customization (combination) Strategies

50 Montage Design Composition

51 Open Building Innovation

52 Montage Building Recipe: 21st Century Skills, Old World Craft Attitude Operating System High skills/craftsmanship 3D software automation OBGrid: Montage Design CNC cutting and shaping Open-Built disentanglement Discipline, Pride Service to society Lean Manufacturing Building Science Constant improvement Custom production Mass Customization High performance Net Zero

53 Project Examples: South Face Village

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65 Project Examples: Coastal Maine Botanical Gardens

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67 The Hole Story

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69 Project Examples: The Design Building at UMass

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73 Even Renovation

74 Small Modules, Combined Modules

75 Bridport House-Hackney Eurban Stadthaus-Murray Grove by Waugh-Thistleton Architects

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77 How to get Started Need site space Deliveries Boom truck or crane Evaluate Access Partners Build a Team Decide where info will live. Different flow to decisions making and commitments Get Everything in Model Early Work the Model Rely on Model

78 Important Differences On-Site Schedule allows for field changes Each step adjusts to previous dimension and (in)accuracy Off-Site Less Design Flexibility Accuracy is paramount - site portion affect install fit Cost may or may not be higher, however time=$ Anticipate need to protect installed finish materials Design the schedule and share extensively

79 A Better Way to Build Montage = Combination of Disparate Elements that Forms or is Felt to Form a Whole, Unified, Singular Image Build time will be 20 days vs days Off-Site Impact: 75% vs 10% to 30% Safe working conditions Consistent working conditions Good Jobs: Discipline, Training, Skills Empowerment; low turnover

80 Questions? This concludes the American Institute of Architects Continuing Education Systems Course Randall S. Walter, AIA LEED AP