Offsite Construction Synopsis Systems, logistics and reasons it makes sense

Transcription

1 Offsite Construction Synopsis Systems, logistics and reasons it makes sense Presented by Ryan E. Smith, Director School of Design and Construction 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 While construction methods have generally remained constant for decades, designers, developers and contractors continually look for ways to build faster, safer and better for less. Although the choice to use on-site wood framing vs. some level of prefabrication depends on many factors, panelized and prefabricated construction can help to meet these goals, offering a reduced construction schedule, improved material efficiency and worker safety, and enhanced quality assurance. With an emphasis on multi-family and commercial projects, this workshop will explore the design implications of wood-frame panelized and componentized construction for architects and engineers. Particular focus will be given to panelized components and trusses, including design and detailing techniques that help teams realize the full benefits afforded by these systems. Project examples, designer-manufacturer interaction and innovative off-site construction trends will also be covered.

4 Learning Objectives 1.Define off-site wood construction and illustrate the various levels of its implementation. 2.Discuss the role of architects and engineers in the success of offsite construction techniques. 3.Review potential cost and schedule savings realized through the use of off-site, panelized wood construction. 4.Highlight how pre-planning and coordination between the design team and component manufacturer for systems such as wall panels and trusses can lead to efficiencies in the fabrication and erection process for panelized and prefabricated wood-frame projects.

5 WHY WHAT HOW WHEN

6 WHY A New Reality For Offsite Construction Why does offsite construction seem viable again?

7 A New Reality for Offsite Construction The last time prefab was taken seriously in America (and elsewhere) was around In 2010, productivity in America dropped to half of 1970 that same year, we saw an increase in interest in prefab.

8 The Economist (McKinsey) Construction holds the dubious honour of having the lowest productivity gains of any industry (McKinsey) In the past 20 years the global average for the value-added per hour has inched up by 1% a year, about one-quarter the rate of growth in manufacturing. Germany and Japan: no growth in productivity France and Italy: productivity fallen by one-sixth America: plunged by half since 1968

9 The Economist (McKinsey) Prices for building materials are not to blame The burden over time of complying with regulation applying for permits, for instance is only partly responsible.* More culpable are two broader structural trends.

10 The Economist (McKinsey) First, the industry has become less capital intensive, with workers replacing machinery. volatility in demand for construction has trained builders to curb investment.

11 The Economist (McKinsey) The second big problem is that the industry has, for the most part, failed to consolidate America: 730,000 building outfits, ten employees Europe: 3.3m, four employees Competition is fierce and profit margins are thinner than for any industry except retail Slim margins make investment even less likely The result is an industry that raises prices for clients and mostly ignores tools that might improve productivity.

12 SITE PROGRAM LABOR

13 Annual % Change - Construction Volume vs. Skilled Labor (National) 15%% 10%% 5%% 0%%!5%%!10%%!15%%!20%% 2005% 2006% 2007% 2008% 2009% 2010% 2011% 2012% 2013% 2014% 2015% 2016% Construc6on%Volume%Percent%Change% Construc6on%Labor%Percent%Change% Courtesy: Cumming Corp.

14 Shift in housing type to multi-family Since 2000, Wolff has invested in, acquired or developed more than 120 multifamily assets and more than 30,000 multifamily units.

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17 $800,000 $1,300,000,000

18 HOSPITALITY MANUFACTURING TECHNOLOGY

19 Source: Quale et al. Construction Matters: Comparing Environmental Impacts of Building Modular and Conventional Homes in the United States. JIE 2012.

20 WASTE 12% VALUE ADDED 10% VALUE ADDED 62% SUPPORT ACTIVITIES 26% SUPPORT ACTIVITIES 33% WASTE 57% MANUFACTURING VS CONSTRUCTION Source: Construction Industry Institute 2011

21 MANUFACTURING CONSTRUCTION Source: US Bureau of Labor and Statistics, 2017

22 WHAT Systems of Offsite Construction What is the scope and definitions of offsite construction?

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24 PREFAB INDUSTRIALIZED MODULAR OFFSITE

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26 PANELIZED

27 Credit: Campbell Construction Group, Glasgow, UK & COCIS Edinburgh Napier University

28 T57G'!+%'?6A.(!U'6/57//!VMW)P!

29 Credit: Campbell Construction Group

30 Courtesy: Landmark Group, Edmonton, AB

31 MODULAR (VOLUMETRIC)

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33 Modular USA 10% HUD Trailer (low end market)

34 Modular USA 2.75% ~2% MBI MHBA PMC Res. modular construction refers to three-dimensional building modules that are prefabricated off site and transported to the site to make up the entire building, rather than prefabricated mechanical systems or wall assemblies.... modular buildings may be Type V (wood frame, combustible) or Type II (steel, concrete, non combustible) and can have as many stories as building codes allow. MBI

35 Modular USA Wood Steel

36 Modular USA 15% of market

37 Volumetric USA Texas 10% HUD Trailer

38 Volumetric USA Pennsylvania 25% of Mod in PA

39 Volumetric USA Northeast

40 HOW Production Systems and Delivery in Offsite How is light wood frame offsite delivered?

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42 detail of the floor panel construction beginnings of gyp board installation module in assembly line with gyp board fully installed floor sheathing installed interior partitions framed out gypsum wall board and stairs installed Sources: Photos, Nicole Radice and Ivan Rupnik 35

43 stair assembly area hydraulic lift used to raise the module tracks in floor for module movement insulation and exterior sheathing applied doors and windows installed millwork and interior finishes applied 36 Sources: Photos, Nicole Radice and Ivan Rupnik

44 D E G R E E O F P R E F A B R I C A T I O N Credit: Interface Architects

45 D E G R E E O F P R E F A B R I C A T I O N Credit: Interface Architects Credit: Interface Architects

46 Credit: Excel Modular, PA Credit: Excel Homes

47 2 Bedroom, 1 Bath Unfurnished = $1300/ Month 2 Bedroom, 1 Bath Furnished = $1380/ Month 3 Bedroom, 1 or 1.5 Bath unfurnished = $1950/ Month 3 Bedroom, 1 Bath Furnished = $2070/ Month Credit: Interface Architects

48 Credit: Interface Architects

49 Credit: Champion Commercial Structures

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51

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53 Credit: Kullmann Building Corp.

54 Credit: Kullmann Building Corp.

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56 Credit: FC Modular

57 Credit: Kullmann Building Corp.

58 WHEN Context of Offsite Construction When is panelized and modular construction ideal?

59 BUSINESS STRATEGIES PI: RYAN E. SMITH, U.UTAH

60 17 PMC

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62 RESEARCH: THE MODULES CASE STUDY 26 % MORE COST EFFECTIVE 44 % FASTER BUILD TIME Image courtesy of IS-Architects

63 RESEARCH: THE MODULES CASE STUDY The Modules Compared Project 9 Months 16 Months 5 Stories Wood 4 Stories Wood 80,000 SF 55,000 SF $12.7 M $11.7 M $ $213.33

64 RESULTS: COST $450.00$ $400.00$ $350.00$ $300.00$ Cost/SF( $250.00$ $200.00$ $150.00$ Modular$ConstrucGon$ ConvenGonal$ConstrucGon$ $100.00$ $50.00$ $0.00$ The$ Modules$ Manresa$ Student$ Housing$ The$ "Stack"$ Starbucks$ Mercy$ Hospital$ STEM$ School$ High$Tech$ High$ Xstrata$ Nickel$Rim$ South$ LEAST AVG MOST -74% 11 % 40 %

65 RESULTS: SCHEDULE 20" 15" Dura%on(in(Months( 10" Modular"ConstrucBon" ConvenBonal"ConstrucBon" 5" 0" The"Modules" Manresa" Student" Housing" The""Stack"" Mercy" Hospital" STEM"School" High"Tech" High" Xstrata" Nickel"Rim" South" LEAST AVG MOST 25 % 42 % 60 %

66 RESULTS: BUSINESS STRATEGIES QUALITATIVE WHY CHOSEN SOFTWARE CHALLENGES LESSONS LEARNED Cost control Schedule reduction AutoCAD: 62% Revit: 23% Other: 15% Permitting and transportation Schedule overruns Early engagement of modular manufacturer Design build contract Design phase modular research by design team

67 TIMBER VOLUME STUDY QUANTIFYING PREFAB WOOD USAGE PI: RYAN E. SMITH CO-PI: DAVID FELL, FPINNOVATIONS

68 PARAMETERS: standard WALLS FLOORS ROOF EXTERIOR 2 X 16 O.C. exterior bearing walls Additional stud at corners, typical (2) 2 X 6 top plate (1) 3 X 6 bottom plate - 1 st & 2 nd level (2) 2 X 6 bottom plate - 3 rd & 4 th level (1) 7/16 OSB sheathing PARTY (2) 2 X 16 O.C. party walls (2) 2 X 6 top plate (1) 2 X 6 bottom plate (2) 7/16 OSB sheathing INTERIOR 2 X 16 O.C. interior partition walls (2) 2 X 4 top plate (1) 2 X 4 bottom plate * Wall and floor framing does not include blocking TJI O.C. Rim joist at floor perimeter 1.25 X 18 LVL Door sills 1.25 X 18 LVL 2 X 16 O.C. joist corridor floor framing (1) 23/32 OSB sheathing 2 X 16 O.C. wood trusses 2 X 4 blocking (1) 19/32 OSB sheathing BUILDING A 47,964 SF over 4 levels light wood frame

69 SUMMARY: soft wood PERCENTAGE VOLUME FACTOR BF / SF STANDARD 0% 2.43 PANELIZED +13% 2.74 MODULAR +19% 2.88

70 SUMMARY: total wood PERCENTAGE VOLUME FACTOR BF / SF STANDARD 0% 4.69 PANELIZED +7% 5.01 MODULAR +69% 7.95

71 NORTH AMERICA Manuf housing Site efficiency 3D modeling Modular SFR SCOTLAND 15% closed panel Affordable Low carbon Sole source MFR HOLLAND Open building Quality of life Rational Shell & infill MFR SWEDEN Optimization Appropriate tech Building science Panelized SFR, MFR, COM GER/AUS/SWISS CNC tools Software integration MMC & Skills Quality SFR, MFR, COM JAPAN Lean manuf Kaizen Precision/Perfection Modular SFR CONTEXT: Cost driven Immigrant labor Small companies Fragmented CONTEXT: Government driven Weather restricted Large companies Integrated CONTEXT: Weather restricted Schedule driven Adaptability Aging in place Fragmented CONTEXT: Performance driven Weather restricted Medium companies $$$ labor & product Integrated CONTEXT: Quality driven Technology oriented Medium companies Fully integrated CONTEXT: Expensive land Expensive labor Manf mind set Large companies (5) LAND LABOR LATITUDE

72 QUESTIONS? This concludes The American Institute of Architects Continuing Education Systems Course Ryan E. Smith Washington State University