Offsite & MMC In
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Offsite & MMC in Affordable Housing - Affordable in MMC & Offsite Offsite & MMC in Affordable Housing A Collaborative Research Project Research A Collaborative A Collaborative Research Project Compiled by Mtech Consult 2 Turning a challenge into an opportunity Foreword by Richard Hill, Director of Programmes & Deputy Chief Executive, HCA We are entering a time when we need to The need for an increased supply of housing, make sure that the money we spend goes however, does not - and should not - mean that further wherever possible. However, what we people ultimately have to settle for a lower quality must not lose sight of is that quality must never of housing. This report includes examples of be sacrificed as a result, and that is the focus where offsite can help deliver consistency of this work. by using advanced technologies to help to reduce errors in construction. “The case studies compiled in the report are exceptional. Adelaide Wharf which is, in Offsite and MMC can offer clear benefits in particular, an excellent example of what the terms of cost, speed of delivery and delivery. integration of different offsite systems can For these benefits to be delivered, it is important achieve. This project was built utilising a number to understand the ways in which offsite can be of offsite technologies, and won awards for used and the different construction processes. design quality. This shows signs of changing This report is an excellent place to understand attitudes towards offsite manufacturing, and its these challenges – and to see excellent ability to be at the centre of outstanding projects. examples of work in this area. It is are not just about bathroom pods, which we have all started to view as “traditional”, but a much broader spectrum of technologies. Richard I hope this educational report will generate debate around offsite and its benefits, and also to challenge some preconceptions. That’s not to say that this report looks purely at the benefits – it also discusses the challenges including that of generating high numbers of repeatable builds. The current changes to the funding of affordable housing may offer greater certainties on volume and this creates an increased opportunity for offsite and other innovative procurement methods. Contents Offsite & MMC in Affordable Housing 4-6 Advanced Timber Frame GreenGauge Homes - Lingwood - Norfolk 7-9 Kingshead - Castlefields - Runcorn 10-11 St Catherine’s View - Fowey - Cornwall 12-13 Closed Panel Timber Frame 3 Astling Green - Blackpool - Lancashire 14-15 Garden Road - Richmond - Surrey 16-17 Open Panel Timber Frame Victoria Villa - Margate - Kent 18-19 Structural Insulated Panel System (SIPS) Gileston Road - St Athan - Wales 20-22 Mid Street - South Nutfield - Surrey 23-25 St Andrews - Surbiton - Surrey 26-27 The Sponsors Affinity Sutton 28-29 ASK Framework 30-31 Dolphin Square Foundation 32-33 Genesis Housing Group 34-35 The Guinness Partnership 36-37 Innovation Chain NW 38-39 Orbit Homes 40-41 Manchester City Council 42-43 Your Homes Newcastle 44-45 Light Steel Frame John Bond House - Tower Hamlets - London 46-48 Kirkham House - Whitby - North Yorkshire 49-50 St George’s Grove - Tooting - London 51-53 Volumetric Modular St John’s Way - Stockton on Tees - County Durham 54-56 Dolwyddelan - Snowdonia - North Wales 57-59 Advanced Concrete Hereward Hall - Fenland - Cambridgeshire 60-61 62/63 Twentieth Avenue - Blyth - Northumberland 62-64 Large Format Blockwork The Pinnacle - Basingstoke - Hampshire 65-67 Rowan House - Sivell Place - Exeter 68-70 Other Adelaide Wharf - Hackney - London 71-73 Stadthaus - Murray Grove - East London 74-77 Conclusions Has Offsite & MMC Delivered for Affordable Housing? 78-80 Offsite & MMC in Affordable Housing - A European Perspective 81-83 Affordable Housing Supply Chain - The Offsiteonline Directory 84-91 An introduction to Offsite & Housing Associations are continually being “What is the learning that can be derived 4 encouraged to use more MMC & offsite from the projects where these systems technologies in their projects, and usage has and technologies have been used?” grown consistently since 2000. The sector has even been a testing ground for many new “Can offsite and MMC be used to reduce systems, but the recent focus on sustainability, the costs associated with achieving the the Code for Sustainable homes (CfSH), and the severe funding position has changed the Code for Sustainable Homes, especially emphasis on the need for buildability. the higher levels?” “Are there better systems that we should consider, that can deliver real cost and sustainability benefits?” It should be recognised that case studies of individual projects will always highlight site specific issues which are difficult to separate out, but by providing a carefully considered list of conclusions, we have focused our attention on the most important aspects of what emerged Although we began by the project by working on seven available technologies that were identified by the sponsors who funded the research, this has expanded to take in additional systems that we believe also warrant consideration. When most people think of MMC or offsite construction, they think of three dimensional volumetric modular blocks of building arriving at The pressure on the affordable housing sector to site on the back of a lorry. Volumetric maximises build more for less has never been greater - this is the work completed offsite in the factory and so true both in terms of cost and CO2 emissions. minimises the work that needs to be undertaken on site. The effect of this is to minimise For the benefit of all those involved in the programme time on site and gain the most of the provision of affordable housing, the time has potential benefits of factory based production. arrived to re-assess where MMC & offsite technology has advanced to as manufacturers Traditionally volumetric construction has been are encouraged to improve their products and the most expensive offsite solution and this has delivery efficiencies in response to the limited its’ uptake in the housing market, but the economic climate. new products which are the subject of the case studies in this report are committed to achieving Mtech, as the UK's only specialist consultancy costs which are truly competitive with traditional for MMC & offsite, engaged nine collaborative forms of construction at the level of true project sponsors and undertook an in depth study of out-turn costs. recently completed affordable housing projects which used these technologies, and here provides answers to key questions that Housing Associations need to consider as they develop their future build strategies. MMC in Affordable Housing 5 Open panel timber frame construction of two thought out and fully detailed solution using and three storey houses has become so common experienced installers and good support from that it is no longer considered an innovative form the supplier. of construction in the social housing sector. It is reliable, routine and generally cost competitive We were encouraged by the number of projects with traditional forms of construction, with a that we identified that were using the more number of users claiming that it gives better advanced timber frame solutions successfully overall project costings than traditional now that and that in most cases they were doing so very they have the processes and supply chains in competitively. This suggests that with further place to maximise the advantages it can offer. development and optimisation of the process The same techniques are widely used to construct these solutions could offer an even greater larger buildings such as flats up to four, five or benefit in terms of quality, performance and cost. even more stories. Structural Insulated Panel Systems (SIPS) This report shows the emergence of more are another panel solution which give an air-tight advanced timber frame solutions, with shell with good thermal performance, and little additional value added in the factory, including cold bridging which is very effective where the insulation, windows, doors, external cladding, etc. design calls for maximised fabric performance to These solutions take more work offsite, with all achieve higher levels of code. The costs involved the normal benefits associated with offsite could be justified by the fact that the finished techniques, and leads to a more rapid, higher panels do not tend to exhibit the shrinkage quality dry envelope. associated with conventional timber frame. The ultimate in advanced timber frame panel is a closed panel system, where in addition to the insulation, windows and doors, the panel is closed off with internal wall linings. This maximises the speed benefit and the work completed offsite, and can start to approach the performance of a volumetric solution, though it does generate a lot more complexity in the jointing and connection details. It is therefore important to use a well (Stadthaus) case study in this report suggests that this premium is now much reduced. The benefits of CLT in a building system are beginning to be appreciated in the UK. Its accuracy and simplicity are being exploited for apartment buildings, schools and other more traditional applications. We are sure that you will find the information contained in this report as interesting and informative as we have 6 The team here at Mtech responsible for the Timber is not the only material suitable for compilation of this publication have found the panelised building techniques. Light Steel Frame exercise interesting, informative and in some (LSF) works in a very similar way, and some would cases surprising. It is our belief that social housing argue has the further advantages of: being a providers throughout the UK will be able to draw more stable material, is typically stronger section valuable lessons from the experience of their for section of comparable size, and can be more colleagues over the last few years. readily sourced in a wider range of structural sizes and strengths.