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Concrete Prefabrication and Offsite Construction in Brazil: a Development Case Study in Mato Grosso

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Concrete Prefabrication and Offsite Construction in Brazil: a Development Case Study in Mato Grosso Concrete Prefabrication and Offsite Construction in Brazil: A Development Case Study in Mato Grosso by Daniel Smicka B.Sc., International Trade, 2011 University of Economics in Prague M.Sc., Entrepreneurship and Innovation, 2014 EMLYON Business School Submitted to the Program in Real Estate Development in Conjunction with the Center for Real Estate in Partial Fulfillment of the Requirements for the Degree of Master of Science in Real Estate Development at the Massachusetts Institute of Technology February, 2021 ©2021 Daniel Smicka All rights reserved The author hereby grants to MIT permission to reproduce and to distribute publicly paper and electronic copies of this thesis document in whole or in part in any medium now known or hereafter created. Signature of Author_________________________________________________________ Center for Real Estate January 8, 2021 Certified by________________________________________________________________ John Kennedy Lecturer, MIT Center for Real Estate Thesis Supervisor Accepted by________________________________________________________________ Professor Siqi Zheng Samuel Tak Lee Professor of Urban and Real Estate Sustainability Faculty Dicrector, MIT Center for Real Estate & Sustainable Urbanization Lab THIS PAGE INTENTIONALLY LEFT BLANK 2 CONCRETE PREFABRICATION AND OFFSITE CONSTRUCTION IN BRAZIL: A DEVELOPMENT CASE STUDY IN MATO GROSSO by Daniel Smicka Submitted to the Program in Real Estate Development in Conjunction with the Center for Real Estate on January 8, 2021 in Partial Fulfillment of the Requirements for the Degree of Master of Science in Real Estate Development ABSTRACT: With a large, growing, and young population, Brazil suffers from a chronic shortage of affordable housing. This crisis, in particular, negatively affects new and economically ascending entrants to the housing market. This economic crisis is unfolding concurrently with the global environmental challenges associated with climate and sustainability. This thesis explores the application of modular construction in an affordable housing project in Cuiaba, Brazil. This thesis is comprised of three distinct sections. Section I provides a historical overview of offsite construction with a particular focus on precast concrete in modular construction. It describes the forces and some of the most notable projects and figures that shaped precast construction - especially in its European cradle. It further provides a comprehensive classification of current modular construction and discusses its benefits and limitations. Section II analyzes Brazil’s ongoing housing crisis and Brazil’s economic trends and realities. It discusses Brazil’s National Housing Policy and its flagship program – Minha Casa, Minha Vida. Section III takes the reader to Cuiaba, Mato Grosso's capital, and proposes a 528-unit affordable housing development project there. It explores the establishment of a mobile concrete precasting plant and analyzes the production and application of a novel modular concrete system in the project. Particular attention is paid to the financial viability of the project. Thesis Supervisor: John Kennedy Title: Lecturer, MIT Center for Real Estate 3 TABLE OF CONTENTS 1. INTRODUCTION ......................................................................................................................................8 1.1. GLOBAL TRENDS .................................................................................................................................. 8 2. WHAT IS MODULAR, WHAT IS OFFSITE, AND WHAT IS PREFABRICATION ............................................. 10 3. A BRIEF HISTORY OF CONCRETE PREFABRICATION ............................................................................... 11 3.1. THE BEGINNINGS ............................................................................................................................... 11 3.2. INDUSTRIAL REVOLUTION ................................................................................................................. 12 3.3. BAUHAUS ........................................................................................................................................... 14 3.4. LE CORBUSIER .................................................................................................................................... 15 3.5. AFTER THE WWII ................................................................................................................................ 17 3.5.1. Eastern Bloc .................................................................................................................................. 17 3.5.2. The Camus System ........................................................................................................................ 18 3.6. AFTERTHOUGHT ................................................................................................................................ 19 4. CATEGORIZATION AND CLASSIFICATION ............................................................................................... 19 4.1. VOLUMETRIC MODULES .................................................................................................................... 22 4.2. NON-VOLUMETRIC MODULES ........................................................................................................... 23 4.3. 2D & 3D HYBRID ................................................................................................................................ 23 5. TRANSPORT AND LOGISTICS ................................................................................................................. 24 5.1. ON-SITE LOGISTICS ............................................................................................................................ 24 6. THE BENEFITS OF MODULAR CONSTRUCTION ....................................................................................... 25 6.1. TIME SAVINGS ................................................................................................................................... 25 6.1.1. Design ........................................................................................................................................... 25 6.1.2. Foundations .................................................................................................................................. 26 6.1.3. Offsite construction ...................................................................................................................... 26 6.1.4. Onsite construction. ..................................................................................................................... 26 6.1.5. Rework .......................................................................................................................................... 26 6.2. COST SAVINGS ................................................................................................................................... 27 6.2.1. Construction costs ........................................................................................................................ 27 6.2.2. Site overheads .............................................................................................................................. 28 6.2.3. Materials. ...................................................................................................................................... 28 6.2.4. Labor force. ................................................................................................................................... 29 6.2.5. Transportation and Logistics ......................................................................................................... 29 6.2.6. Factory costs ................................................................................................................................. 29 7. BRAZIL .................................................................................................................................................. 30 7.1. ECONOMY OVERVIEW ....................................................................................................................... 30 7.2. ORGANIZATION ................................................................................................................................. 33 7.3. POPULATION...................................................................................................................................... 34 7.4. INCOME DISPARITIES ......................................................................................................................... 36 8. REAL ESTATE MARKET........................................................................................................................... 37 4 8.1. RESIDENTIAL MARKET ....................................................................................................................... 38 8.2. HOUSING DEFICIT .............................................................................................................................. 39 8.3. HOUSING POLICY - MCMV ................................................................................................................. 40 8.4. HOUSING FINANCIAL SYSTEM AND ITS ACTORS ................................................................................ 40 8.4.1. Federal Government ..................................................................................................................... 41 8.4.2. The Ministry
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