FEATURE

The images in this story are from AE Smith’s installation of a prefabricated module into the Lady Cilento Children’s Hospital (LCCH). Image: AE Smith.

to implement, think again. As our three proponents of prefabricated and modular building techniques explain, the devil Fabricating is in the detail. We spoke to AE Smith national BIM operations manager Mark Jacobson, M.AIRAH, Warwick Stannus, M.AIRAH, group engineering manager for A.G. the future Coombs; and Nick Stavroulakis, M.AIRAH, mechanical project engineer, The use of prefabrication and modular building techniques associate for Wood & Grieve Engineers.

in the HVAC industry is growing, and for good reason. As well Ecolibrium: Is the use of as leading to more accurate assembly, the process typically prefabrication in reduces costs and risk. Sean McGowan spoke to some leading becoming more common, and why? proponents about the planning behind this evolving process. WS: The use of prefabrication in Australia is continuing to grow; however, we still have some way to go to catch up Though slower to adopt prefabricated projects – from commercial office to the levels of adoption seen in North building techniques than our buildings and residential accommodation America and the UK. Notwithstanding international counterparts in North to data centres and healthcare facilities. the relatively slow take-up to date, offsite America, Europe and Asia, the Australian For instance, projects such as the fabrication is starting to play a major construction industry is now making Queensland Children’s Hospital role in the delivery of healthcare projects rapid ground. energy plant (as featured in Ecolibrium, around the country. On the back of the wider application October 2013) demonstrate advantages of building information modelling such as leaner construction timeframes, While there is no doubt that the (BIM) and 3D modelling, and a push reduced waste, quality improvements percentage of work completed offsite will and significantly lower safety risks. for construction cost efficiencies, continue to increase as the industry seeks prefabrication of multiple services But if you thought the alternative to to lower costs and de-risk projects, it is is finding its way into many types of traditional “stick build” methods is easy likely that the Australian construction

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Studio at the Bendigo Hospital, which been operating for some five years and  features 66 hotel rooms over four storeys. combines specialist pre-fabrication design As the Australian The hotel component was installed onsite expertise with flexible and adaptable construction in just six days. manufacturing processes. industry becomes WS: The development of our modern MJ: AE Smith utilise prefabrication more collaborative, prefabrication capability is closely aligned to streamline the quality and delivery with our investment in BIM as our design of multiple services within buildings the more we and construction platform. such as hospitals, high-rise buildings, education buildings, research facilities will embrace While there has been some element of and data centres. this form of offsite prefabrication in A.G. Coombs projects for many years, all our major This approach allows for parallel construction projects in the last four or five years manufacturing techniques, and has have incorporated significant offsite the added benefit of precommissioning fabrication components including plant and in some cases, commissioning of room modules, risers, services racks skid-mounted equipment sets. The sector will combine best practices from and sub-assemblies. Our large, dedicated earliest modularisation system employed both the US and UK to develop its own offsite fabrication facility has now by AE Smith was on the Woodford unique approach to offsite fabrication. MJ: It is very dependant on the design consideration given to the application of modularisation. This approach is becoming more the mainstay as designs evolve and services contractors work towards a more collaborative construction environment, and reap the benefit due to improvements in productivity. The greatest advantages can be obtained where spaces contain multiple services within common areas and plant rooms, but in truth, it is only limited to the designers imagination. NS: Another area is modular construction, which is prefabrication on a larger scale where we are constructing modules or building blocks that can be transported on a semi-trailer, train or ship to site. Typically two to three modules are combined to create an apartment or similar, which have almost all the internal fittings and finishings completed and are virtually ready to move into once the connections between modules and to the site are made.

Ecolibrium: How long has your firm used prefabrication? NS: Wood & Grieve have been involved with partial prefabrication of some components for as long as I can remember. We’ve been involved in the modular construction industry since 2010 and have delivered several large projects, the vast majority of which have been with our modular partner Hickory Building Systems. These include a six-storey residential building of 77 apartments in South Hedland, WA, and The Schaller

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In some cases, prefabrication can cut installation time in half. Image: AE Smith.

Correctional Centre in 1996, where occur with little impact on the critical Ecolibrium: Does prefabrication the entire roof structure including path of the construction program lead to improved quality and services was prefabricated separately in a safe work environment. accuracy of work? to the core building. NS: For the contractors it’s easier and NS: In my mind, the biggest advantage more comfortable to build this way, is safety. Even with recent improvements Ecolibrium: What are the key so work quality is better. benefits and advantages of in site safety, conventional construction WS: Accuracy is a key benefit as well prefabrication? is still a risky business, and anything we can do to make it safer is worthwhile. as being an issue that needs to be WS: Offsite prefabrication helps reduce carefully managed. Prefabrication tends construction programs that can deliver to be built to manufacturing tolerances. significant project savings. With work completed on site, there is Without Overseas data indicates offsite always a degree of site measure and fabrication can lead to direct cost coordination, problem solving that necessitates an as-built validation process. With the use savings in the order of 10 to 15 per cent you will end when executed effectively. In some of prefabrication and site lay-out tools such as Trimble, this time-consuming instances, the labour savings can be up reworking process is significantly reduced. dramatic – cutting the installation time entire modules, MJ: Due to the controlled environment, by as much as 50 to 60 per cent – however, which is a this must be offset against additional the prefabricated product is typically costs involved in framing, etc. very expensive far superior to the site-built equivalent. Sub-components can be manufactured site activity In today’s market, it is just as important within the workshop by utilising for us to be able to de-risk projects construction jigs that ensure each and by completing more of the work in every component is millimetre-perfect, a controlled environment offsite. While prefabrication and modular thus significantly reducing the need for MJ: The commissioning activity can construction will not eliminate all site-measured components. also occur as a concurrent process, safety risks, by prefabricating in a Ecolibrium: What are the downsides allowing the early identification of controlled environment, risks such as and issues for consideration? potential performance and quality manual handling are reduced by providing WS: Due to size and weight constraints, assurance issues. As these issues are good lifting equipment, and falls from compromises in offsite fabricated plant- identified in a controlled workshop heights can be substantially reduced room modules can occur with regard to environment, corrective actions can by having safe work platforms. plant access and maintenance provisions.

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Off-site prefabrication is on the rise. Image: AE Smith.

It’s important that detailed safety in Fire ratings can also be more complicated, are always site connections – connections design reviews be completed – this can as the BCA wasn’t written with modular between modules and large items of plant be completed more effectively in the construction in mind. We have overcome that need to be installed on site. These 3D modelling environment. In some this through close collaboration with our can be quite challenging, but we are always instances we have also used 3D printing fire engineering team, the contractors and coming up with better ways to do them. to assist clients understand the design the manufacturers of passive fire-control It really is a matter of identifying what from a maintenance access perspective. systems. is better to prefabricate and what is better Construction tolerances and site layout to be done onsite. are also critical if prefabrication is to be successfully utilised. The greatest NS: The extent to which we use offsite fabrication continues to increase. Come and celebrate ActronAir’s 30th anniversary MJ: If the design does not contain the advantages can However, site-installation practices are approach for prefabrication, it becomes at ARBS. Some of our latest innovations will be be obtained where also improving through use of recently ™ quite difficult to retrofit this idea once the introduced technologies such as point on display, including Hercules, ESP Platinum structural design has been finalised and spaces contain layout systems and copper press fittings and ActronConnect. You can also enter a draw the construction methodology has been multiple services that both support as well as off-set the to win a Hot Lap with 2013 Bathurst winner, and defined. within common potential benefits that can be gained ActronAir Ambassador, Mark Winterbottom. The lifting capacity of the crane is also through the use of prefabrication. areas and plant See youyou at Stand 290! Visit actronair.com.au. important, and consideration must be Prefabricated risers can have a significant given to the size of the site module set- rooms, but in truth, impact on the structural design of the down areas. it is only limited shafts, and hence if prefabrication is to “Come“Come andand seesee thethe be utilised it is always preferable to have Peter Brock TrophyTrophy att WS: Prefabrication can also lead to to the designers more complex critical paths, and it is not the shafts designed to accommodate a thethe AcActronAirtronAir ststand.”and.” imagination prefabricated system from the outset. unusual for prefabricated components Mark Winterbottom such as riser modules to appear on MJ: The amount of site work required the critical path, either on the core will depend on how well the design construction program and/or floor fit-out Ecolibrium: Concerning HVAC plant, integrates with the finishes of all services. program. what are the areas where offsite In the US I have seen a foyer module that NS: Due to the speed of construction, fabrication is unable to replace work included the bulkhead wall with the jet there is less time to respond to issues, done onsite? diffusers already fitted – and the only so things can get quite hectic for the NS: Onsite fabrication will always be work left to be completed was the setting, designers and constructors. required. In the modular situation, there sanding and painting of the wall.

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140367 ActronAir Ecolibrium Visit Us at ARBS HP FINAL.indd 1 7/04/14 11:55 am FEATURE

adherence to construction tolerances must be achieved in all areas of construction. NS: There is no point prefabricating offsite only to bring equipment onto site and have to pull it apart and modify it because it doesn’t fit onsite. This applies to all trades.

Ecolibrium: How is the use of BIM related to prefabrication? WS: Building information modelling Size of set-down areas, as well as crane lifting capacity, must be considered. Image: AE Smith. (BIM) is the key to offsite fabrication, as without coordination certainty the Typically in Australia, the prefabrication site activity. The earlier the involvement additional investments needed in offsite process focuses on the bones of a system, by all trades, the easier the process fabrication design, framing and logistics with the fit-off being the final site- becomes. can be easily wasted. construction phase. WS: Accuracy is critical. Central For our PPP (public-private partnership) to prefabrication is the virtual build Ecolibrium: Does this technique projects, and where we are appointed to process, and this must then be accurately place greater importance on the the project team early, we often provide replicated onsite. accuracy of all trades on site? prefabrication models to the design MJ: Very much so. Without It is very difficult to modify prefabricated team to allow them to utilise the frames coordination, you will end up reworking assemblies once manufactured and within their design documentation. entire modules, which is a very expensive delivered to site; therefore, strict We also work closely with the architects

140367 ActronAir Ecolibrium Visit Us at ARBS HP FINAL.indd 1 7/04/14 11:55 am FEATURE

On-site fabrication will always be required – modules and large plant items need to be connected. Image: AE Smith.

and structural engineers to assure that prefabrication is incorporated with the – although clearly it is better if everyone is prefabrication modules are efficiently building’s design, the greater the benefits fully engaged in the virtual build process. accommodated within the design. to the delivery and operation of the building. Ecolibrium: What are the planning MJ: BIM or at least 3D modelling is implications and workflows of critical. It allows us to design to a higher Ecolibrium: Is offsite fabrication prefabrication? level of accuracy, and to coordinate better possible where BIM is not applied? between trades and structure than we can NS: When we design modular, we What are the minimum requirements with 2D CAD. are often designing multiple streams around modelling and virtual build? in tandem. For example, we may be MJ: You can produce fully coordinated designing site infrastructure and prefabricated modules by using the The labour savings negotiating with authorities and at the “B” and “M” of BIM. This has been the same time working with the contractors can be dramatic approach by the majority of the industry’s to finalise our module design, inspecting – cutting the contractors for many years. When the prototypes and finishing modules before information component is included any works on site have commenced. installation time within the model, design alternatives can As the timeframes can be shortened so by as much be quickly appraised for suitability. This approach leads to a superior design than dramatically, this can be challenging as 50 to just a 3D-coordinated drawing. for all. However, when you can see 60 per cent construction times, such as The Schaller NS: Smaller assemblies can definitely Studio, where 66 hotel rooms were be documented in 2D; however, we have installed over four levels in just six days, found that these require more physical the challenge is worth it. When designing, not only do we need to prototyping. When we have 3D modelling think about the final installation, but how available a lot of this prototyping can be WS: Prefabrication works best when the components can be broken down into done in the model. the design process fully incorporates modules or assemblies, how to transport prefabrication strategies from the start, them to site and get them into place, how Modelling time is much cheaper than rather than as a value-engineering proposal the connections work and then finally materials and site labour, so the better we during tendering and/or construction. what the final solution will look like and can prototype in the model, the more we how it will work. save in real life. NS: By using an information-rich model, WS: It is not something we would tend Need to know the design process will progressively to consider. While some trade contractors Warwick Stannus will be part evolve to align with the special and will only commit to BIM if required by of a panel session to discuss BIM performance requirements of the the contract – we will commit to “lonely” at ARBS. project. As already mentioned, the earlier BIM because of the benefits it still delivers

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We have developed detailed BIM and team, which now includes the mechanical prefabrication design management plans contractor, allows the prefabrication  that allow us to work with design teams design to be appraised at a much earlier Prefabrication to facilitate the integration of multiple stage of the project’s life. works best when services onto prefabricated horizontal One of the major benefits of this is a the design process frames and risers. This extends to reduction in the design timeframe, thus prefabrication design development, fully incorporates allowing for a faster transition into the structural analysis and approvals. construction phase. prefabrication While one of the key benefits of offsite strategies Ecolibrium: What impact does prefabrication is that manufacture can from the start occur in parallel with the structure on prefabrication have on employment site, to enable this to happen it is critical numbers? Do the higher efficiencies that the design be completed ahead of lead to a smaller workforce? the site structure. Prefab fixings tend MJ: There will be a shift from site to our skilled tradespeople either on site or to carry significantly more weight than factory, but the fit-off works will still in the prefabrication facility, depending traditional hangers and it is therefore require a substantial workforce. With the on the project work profile. highly preferable to locate the fixings improvement in productivity, the ability before the slab pours as well as ensure to carry out more work with the same NS: There is a shift in skills and types of pipework anchors are cast into shaft walls staff numbers will only reinforce the work but we don’t see a great reduction in where required. benefits of prefabrication. the number of workers. But we do see them being much more efficient with their time. MJ: We work closely with the structural WS: Clearly, increased use of On a conventional building, the amount and services design team from the prefabrication is reducing the amount of time wasted in simply getting up, down design inception to ensure the project of labour required on site; however, our and around a high rise construction site is can support prefabrication. This design approach to prefabrication aims to utilise a huge portion of the overall time. FEATURE

20 - 22 May, 2014 Convention & Exhibition Centre

Pre-fab may cause a shift in skills, types of work, and where that work is carried out. Image: AE Smith.

Ecolibrium: What is the future of can remain competitive on a global scale Use of offsite modular construction prefabrication for our industry? and export this technology overseas as will also increase. Where might it lead to? well as into new markets. Based on experience, we believe NS: It has a bright future in Australia WS: There can be little doubt that that prefabrication will continue – it will make construction safer, less an increasing amount of project work to play a major role in all our projects wasteful, more efficient in materials, cost will be completed offsite in prefabrication moving forward, and will work hand-in-hand with our use of BIM and time. As we continue to innovate, we facilities, following the UK and US trend. and innovative site-installation practices. MJ: We only have to look at what is being achieved overseas. In Asia, FLAGSHIP PROJECTS most of the modules are on a grand scale and include all items in a finished state. Listen, learn, network UTILISING PREFABRICATION This approach further accelerates the fit-out of the building services to a point Australia’s ONLY international Air Conditioning, Refrigeration and AE Smith where the construction of the building Darwin Onshore LPG Processing Plant, NT (Infrastructure) becomes the main bottleneck. Building Services trade exhibition is returning to Melbourne in 2014 AEB, University of Queensland, Qld (Education/Research) I see that as the Australian construction industry becomes more collaborative, Registrations are now open for the ARBS 2014 seminar program. Queensland Children’s Hospital Energy Plant, South Qld (Health) the more we will embrace this form of construction. The design process needs From breakfast panel discussions to “just the facts” information sessions, A.G. Coombs to start with this construction method there are more than 20 opportunities for your continued professional development, 735 Collins Street, Melbourne, Vic (Commercial) to realise the major benefits that can be Royal Children’s Hospital, Melbourne, Vic (Healthcare) leveraged from this approach. ❚ information and networking. Melbourne Markets Relocation Project, Melbourne, Vic (Infrastructure) Telstra Data Centre, Vic (Data) Mark Jacobson, M.AIRAH National BIM operations manager See the full program or register NOW at Bangaroo South, , NSW (Multi-use) AE Smith Wood & Grieve Engineers Warwick Stannus, M.AIRAH www.arbs.com.au Group engineering manager The Schaller Studio, Bendigo Hospital, Vic (Hotel) A.G. Coombs Follow us Concord South, South Hedland, WA (Residential) Nick Stavroulakis, M.AIRAH Mechanical project engineer; associate Duffy Primary School Learning Centre, ACT (Education) Wood & Grieve Engineers ARBSexpo @arbsexpo Arbs Exhibitions Limited

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122-ARBS Seminar Ecolibrium ADV 210x297+3.indd 1 20/03/2014 12:56 pm FEATURE Rising to the occasion Last year A.G. Coombs installed a 10-storey prefabricated riser. It took four days to do it, but saves months of work.

Eighteen three-storey interlinking sections were trucked in, each weighing up to 3.5 tonnes.

The pre-fab multi-services riser was 18m wide, 3m deep and 10 storeys high. The installation of Australia’s largest prefabricated multi-services risers was completed in record time by A.G. Coombs at a large project in Melbourne last year. Measuring 18m wide, 3m deep and 10 storeys high, the complex prefabricated services riser was installed over a four-day period. Full onsite installation of this riser would have normally extended to several months. Manufactured in eighteen three-storey-high interlinking sections each weighing up to 3.5 tonnes, the riser was transported by road from A.G. Coombs’ large dedicated off-site prefabrication facility in Moorabbin, and crane-lifted into place on site. The multi-services riser was manufactured and installed as part of A.G. Coombs’ role as specialist design and construct mechanical and HVAC contractor on the project. “Incorporating air conditioning and complex exhaust ductwork, including specialist PC4 exhaust systems natural gas and other building services, the risers were designed by A.G. Coombs using 3D CAD and BIM software to benefit from advanced prefabrication methodologies,” says A.G. Coombs strategic development director Bryon Price, M.AIRAH. “A.G. Coombs prefabricates integrated multi-services risers and runs, plant assemblies and other building services system Australia’s largest prefabricated multi-services riser is lifted components to exacting standards to ensure quality and accuracy, into place in record time. Images on this page courtesy of A.G. Coombs. leading to ease of manufacture, installation and commissioning.” ❚

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