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ISBU Modular Construction and Building Design Prototypes ISBU Modular Construction and Building Design Prototypes Adrian Robinson Buro Happold Engineers Ltd Centre for Innovative and Collaborative 17 Newman Street Construction Engineering LONDON Department of Civil & Building Engineering W1T 1PD Loughborough University Loughborough Leicestershire, LE11 3TU ISBU MODULAR CONSTRUCTION AND BUILDING DESIGN PROTOTYPES By Adrian Robinson A dissertation thesis submitted in partial fulfilment of the requirements for the award of the degree Doctor of Engineering (EngD), at Loughborough University January 2017 © by Adrian Robinson 2017 Buro Happold Engineers Ltd. Centre for Innovative and Collaborative Construction 17 Newman Street Engineering LONDON Department of Civil & Building Engineering W1T 1PD Loughborough University Loughborough Leicestershire, LE11 3TU Acknowledgements ACKNOWLEDGEMENTS I would like to acknowledge the help and assistance of my academic supervisors at Loughborough University: Prof Alistair Gibb, Prof Simon Austin and Prof Jacqui Glass and the examiners for their constructive comments. I would also like to thank Dr Mike Cook of Buro Happold, Dr Mick Green and Mr Martin Walsh formerly of Buro Happold, and Mr Tony Swindells of KKA Architects for their support and advice during my studies for this doctoral thesis. Finally, I would like to give special thanks to Jill Gascoigne for patiently checking the text for minor errors and corrections; any further errors are mine. i ISBU Modular Construction and Building Design Prototypes ABSTRACT With the use of industrialised construction increasing, Buro Happold (BH) commissioned this research as part of on-going initiatives to address the lack of efficiency in design and construction. The research considers two major case studies where modularisation has been used to minimise complexity and increase standardisation. Referred to in this thesis as ‘construction product prototypes’ and ‘building design prototypes’, the two studies examine firstly the product development of an Intermodal Steel Building Unit (ISBU) used in multi- storey construction and secondly a modular station pre-design used and repeated on four station buildings. The ISBU is based on a standard ISO dry-freight container and its use in modular construction maximises the use of factory based off-site methods (OSM); this should improve consistency of product outcome with minimised impact on site. Very little academic work has been published on ISBU modular construction. The research therefore looks in detail at the process of ISBU modular product development and its engineering performance. It also compares production and procurement of the units on supplier-driven accommodation buildings in comparison to similar but non-modular client-led projects. Using multiple stages of project team interviews and project document analysis, the research data is coded, measured and analysed to describe the processes of product and design prototyping. The research demonstrates that the ISBU product was developed and refined through several major building projects and has reasonable engineering performance characteristics but may be more suited to temporary buildings. The principle of modular pre-designs as found in stations has benefits for rationalising the design process and simplifying and internalising complexities of construction. The research considers solutions for problems that are ill defined and a design process that is difficult to assimilate. This part of the research uses models for framing and problem/solution co-evolution to solve problems of ill definition and linear/non-linear design processes by building on Gero’s (1990) design prototyping theory model. Modularisation of the station designs was successful in reducing design effort and allowed a repeatable pre-design to be refined, but the design team struggled with the bespoke nature of the project designs. The comparison of case study data to models for manufacturing, procurement and design prototype development has led to a better understanding as to how these designs were achieved and how these same approaches could be applied in future. KEY WORDS Off-site Construction, Design, Prototyping, Product Development, Shipping Containers, Modularisation. ii Preface PREFACE This research began in 2007 and was completed in 2016, in partial fulfilment of the requirements of the Engineering Doctorate (EngD) at the Centre for Innovative and Collaborative Engineering (CICE), Loughborough University. The research was conducted within an industry context and sponsored by Buro Happold Consulting Engineers. The EngD is examined on the basis of this discourse, supported by five peer-reviewed publications. Presented within the appendices section of this thesis are four conference papers and one journal paper, all of which were authored by the candidate. The main body of the text provides an in-depth overview of the work undertaken, the context, findings and implications for the sponsor and industry. Further details are explained within the papers included in the appendix section. iii ISBU Modular Construction and Building Design Prototypes USED ACRONYMS / ABBREVIATIONS 2D Two-Dimensional 3D Three-Dimensional ACSA American Collegiate Society of Architects AI Artificial Intelligence ARCOM Association of Researchers in Construction Management BAA British Airports Authority BIM Building Information Modelling CABE Commission for Architecture and the Built Environment CAD Computer Aided Design CAM Computer Aided Manufacture CIB Conseil International du Bâtiment (now International Council for Research and Innovation in Building and Construction) CIMC China International Marine Containers Group Ltd. CIRIA Construction Industry Research and Information Association CtO Concept to Order dB Decibel Level DD Double Diamond Product Design Model DEFRA Department for Environment, Flood & Rural Affairs DfMA Design for Manufacture and Assembly DtO Design to Order ER Essential Requirement (see ETAG) ECAM Engineering Construction and Architectural Management EOTA European Organisation for Technical Approvals ETAG European Technical Approvals Guidelines EtO Engineer to Order IBS Industrialised Building Systems ISBU Intermodal Steel Building Unit LCA Life Cycle Assessment LOR Laing O’Rourke MMC Modern Methods of Construction MtC Make to Concept MtF Make to Forecast MtO Make to Order NSSS National Structural Steelwork Specification for Building Construction ODPM Office of the Deputy Prime Minister OSM Off-Site Manufacturing UK United Kingdom iv Table of Contents TABLE OF CONTENTS Acknowledgements .................................................................................................................... i Abstract ..................................................................................................................................... ii Key Words ................................................................................................................................ ii Preface ...................................................................................................................................... iii Used Acronyms / Abbreviations............................................................................................. iv Table of Contents ..................................................................................................................... v List of Tables and Figures .................................................................................................... viii List of Papers .......................................................................................................................... xii Definitions .............................................................................................................................. xiv 1 Background to the Research ........................................................................................ 1 1.1 Introduction ..................................................................................................................... 1 1.2 Research Context ............................................................................................................ 2 1.2.1 History of modular construction and off-site systems ...................................... 3 1.2.2 Pre-designs & building design prototyping ....................................................... 8 1.3 The Industrial Sponsor .................................................................................................. 10 1.3.1 An international multiple disciplinary practice ............................................... 10 1.3.2 Containerised Construction Projects ............................................................... 12 1.3.3 Modular station projects based on pre-designs ............................................... 14 1.4 Aims and Objectives ..................................................................................................... 16 1.4.1 Research aims .................................................................................................. 16 1.5 Achievement of objectives through workpackages ...................................................... 17 1.5.1 Scope of research ISBU modular product development (WP 1) .................... 19 1.5.2 ISBU technical product development (WP 2) ................................................. 19 1.5.3 Commercial application of ISBU module (WP 2b) ........................................ 19 1.5.4 Building design prototyping (WP 4) ..............................................................
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