PREFABRICATION - WoodWorks · construction or any method or manner of handling, using, ... solid...

PREFABRICATION: Ryan E. Smith, Associate Professor Director ITAC, University of Utah Chair of the Off-Site Construction Council, National Institute of Building Sciences March 11, 2015

Disclaimer: This presenta1on was developed by a third party and is not funded by WoodWorks or the So=wood Lumber Board.

OFF-SITE STUDIES

Discoveries in Off-Site Construction Techniques

Photo Credit: MKD

“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.

Course Description

Off-site construction techniques, including both light-frame and solid wood solutions, are continually evolving—with prefabrication at the forefront of the trend. In this presentation, different types of prefabrication will be discussed, along with key considerations—such as site, cost and schedule to determine which option, if any, is right for a project. Case study examples will be used to illustrate key principles of practice, benefits of prefabrication and current challenges.

Learning Objectives 1.  Attendees will be able to understand the various prefabricated wood systems

available for specification and when is most appropriate given site, location, labor, cost and schedule considerations in today’s construction market by evaluating construction performance parameters and examples of case studies.

2.  Learners will be able to understand and apply knowledge of solid timber wood solutions (i.e. CLT, LVL, SCL, etc.) to architectural projects through examples of details and case studies.

3.  Participants will be able to identify the benefits and challenges of factory produced light wood frame panel construction with integrated insulation, services, and finishes.

4.  Attendees will be able to distinguish digital workflows in wood design and fabrication and how to properly collaborate and partner with timber fabricators to achieve desired results through a demonstration of the landscape of digital options in timber that make the bridge between ideation and production.

Photo Credit: R.E.Smith

Photo Credit: Interface Architects

WHY WHAT HOW WHEN

WHY WHAT HOW WHEN ARGUMENTS

WHY WHAT HOW WHEN ARGUMENTS CATEGORIES

WHY WHAT HOW WHEN ARGUMENTS CATEGORIES ASSEMBLY

WHY WHAT HOW WHEN ARGUMENTS CATEGORIES ASSEMBLY TRADE-OFFS

Paul Teicholz, Stanford CIFE Excerpted from: R.E.Smith Prefab Architecture (Wiley 2010)

SITE BUILDING LABOR

Source: ITAC UofU

MANUFACTURING CONSTRUCTION

Source: US Bureau of Labor and Sta0s0cs Graphic: ITAC UofU

!20%%

!15%%

!10%%

!5%%

0%%

5%%

10%%

15%%

2005%

2006%

2007%

2008%

2009%

2010%

2011%

2012%

2013%

2014%

2015%

2016%

Annual % Change - Construction Volume vs. Skilled Labor (National)

Construc6on%Volume%Percent%Change% Construc6on%Labor%Percent%Change%

Courtesy: Cumming Corp.

ELEMENTS USED IN LAST 12 MO?

Source: NIBS OSCC

NEXT 12 MO?

WHAT ?

NORTH AMERICA Manuf housing Site efficiency 3D modeling Modular SFR CONTEXT: Cost driven Immigrant labor Small companies Fragmented

SWEDEN Optimization Appropriate tech Building science Panelized SFR, MFR, COM CONTEXT: Performance driven Weather restricted Medium companies $$$ labor & product Integrated

JAPAN Lean manuf Kaizen Precision/Perfection Modular SFR CONTEXT: Expensive land Expensive labor Manf mind set Large companies (5)

SCOTLAND 90% panelized Affordable Low carbon Sole source MFR CONTEXT: Government driven Weather restricted Large companies Integrated

GER/AUS/SWISS CNC tools Software integration MMC & Skills Quality SFR, MFR, COM CONTEXT: Quality driven Technology oriented Medium companies Fully integrated

HOLLAND Open building Quality of life Rational Shell & infill MFR CONTEXT: Weather restricted Schedule driven Adaptability Aging in place Fragmented

Credit: ITAC UofU

ELEM

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COMPONENTS

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MODULES

MATERIALS

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COMPONENTS

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MODULES

MATERIALS

parts

sub-assemblies

assemblies

point of final assembly

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5000

Source: Bensonwood

50 TO

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COMPONENTS

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GLT SCL CLT

DLT NLT CNLT ICLT

GLUE

D NO

N-GL

UED

POST & BEAM SOLID WOOD (mass timber, mass wood) HYBRID COMPONENTIZED WOOD SOLUTIONS

Credit: COCIS Edinburgh Napier University & ITAC UofU

SOLID-WOOD BARRIERS SOLID-WOOD UPTAKE

Credit: COCIS Edinburgh Napier University & ITAC UofU

= 15,300 houses

766,943 Units

by ~2030

Source: A.C. Nelson, ‘The Boom To Come, America Circa 2030’.Architect, 95, no. 1

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Source: U.S. Census Data 2000 – 2010

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Adapted from Utah State Environmental Regula0on 2008 data

30% = 15%

Concrete/Mixed

Rubble, 40%

Wood, 30%

Drywall, 10%

Asphalt Roofing,

8%

Metals, 4% Bricks, 4% Plastics, 4%

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C&D Waste = 940,264 Tons

20-30% yield = 235,066 Tons

Feasibility Rate 30% = 70519.8 Tons Typical CLT House = 60-70 Tons

# of potential houses = 1085 Homes

C&D Waste = 940,264 Tons

20-30% yield = 235,066 Tons

Feasibility Rate 30% = 70519.8 Tons 2700 S.F. House = 6,921 cu ft. wood

Density of pine wood = 33 lbs / cu ft.

# of potential houses = 617 Homes

=

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= 2 million acres

2006 2007 2008

1.0

1.5

2.0

Source: Colorado State University Report No. 5.528

44%

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Area = 1,000,000 acres

Trees (50 / acre) = 50,000,000 trees

Board feet = 1695 B.F. / tree

Board feet total = 84,750,000,000 B.F.

B.F. / House = 40,000 B.F.

# of potential houses = 2,118,750 Homes

80’

3’

Adapted from DOA U.S. Forest Service Data +

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Ashby, Materials and the Environment

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2 Ply: 5.5”

3 Ply: 8.25”

4 Ply: 11”

5 Ply: 13.75”

Credit: Euclid Timber +

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Credit: Euclid Timber +

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Credit: Brigham Young University & Acute Engineering +

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Credit: Sam Glass, USDA Forest Products

Laboratory +

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3-PLY ICLT WITH EXTERIOR INSULATION

Exterior to interior: •  Composite wood siding •  Drainage cavity/ventilated air space •  R-10 insulation •  Vapor-permeable air barrier membrane •  3-ply ICLT with no interior finish

Vapor-open Mineral wool

Vapor-tight Extruded polystyrene

Credit: Sam Glass, USDA Forest

Products Laboratory

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Credit: Euclid Timber

Credit: Euclid Timber & ITAC UofU

Credit: Girl Scouts of Utah & ITAC UofU

Credit: Euclid Timber & ITAC UofU

Credit: Girl Scouts of Utah, ITAC UofU, & AJR Al0er

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Credit: Euclid Timber, Girl Scouts of Utah, ITAC UofU, & AJR Al0er

Credit: Euclid Timber, Girl Scouts of Utah, ITAC UofU

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Credit: Scob Hedges via Linddbeck

PANELS

CLOSED VS. OPEN ENHANCED VS. STANDARD HYBRID SUBASSEMBLIES

- Wall panel - Floor cartridge - Roof cassette

Credit: Campbell Construc0on Group, Glasgow, UK & COCIS Edinburgh Napier University +

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Image Credits: Weinmann HOMAG

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Credit: Campbell Construc0on Group +

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Credit: Bensonwood & Unity Homes +

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MODULES “VOLUMETRIC”

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RESIDENTIAL / COMMERCIAL TEMPORARY / PERMANENT IN-LINE / STATIONARY DEALERS / MANUFACTURERS

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Credit: Simplex Homes, Zeta Communi0es & Pacific Mobile

Credit: Interface Architects

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First Green building in the Temple University Area LEED Gold rating Client – Templetown Realty Architect – Interface Studio Architects, Philadelphia PA Contractor – Equinox MC Fabricator – Excel Homes Site Area – 16,000 Sq. Ft. Building Area – 70,000 Sq. Ft.


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Credit: Excel Modular, PA

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Credit: Excel Homes

Credit: Interface Architects +

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Credit: Interface Architects +

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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

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Image Credit: Interface Architects Source: ITAC UofU +

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Credit: KYA Architects +

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Credit: KYA Architects, Mspace, Britco

Credit: Simplex Homes

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Source: ITAC UofU

Source: ITAC UofU

Modular Factory Sequence

Credit: Simplex Homes, Irontown Homes, Blazer Industries

OFF-SITE BARRIERS

Source: NIBS OSCC

!!

Source: RE Smith, Prefab Architecture (Wiley 2010)

Source: Kullmann Design Guide

Standard Flatbed 8.5’ wide x 8.5’ high x 54’ long

Single-drop Deck 8.5’ wide x 10.5’ high x 50’ long

Double-drop Deck (low-boy) 8.5’ wide x 15.5’ high x 40’ long

Source: R.E. Smith, Prefab Architecture (Wiley, 2010)

Image Credit: Egoin

Credit: BluHomes, Vallejo, CA

Credit: Scob Hedges

Source: R.E. Smith, Prefab Architecture (Wiley, 2010)

WHEN ?

TEAM

TYPE

PLACE

Experience Control Repetition Manufacture Financing

Source: RE Smith. Prefab Architecture (Wiley, 2010)

OFF-SITE BARRIERS

Source: NIBS OSCC

STAKEHOLDER COLLABORATION

Source: NIBS OSCC

STAKEHOLDER COLLABORATION

Source: RE Smith, Prefab Architecture (Wiley 2010)

DOES OFF-SITE AID IN MEETING THE COST, TIME, LABOR, SITE AND PROGRAMMATIC GOALS FOR THE PROJECT?

Credit: ITAC UofU

IS THE PROJECT DESIGNED IN AN INTEGRATION WITH STAKEHOLDERS FOR OFF-SITE MANUFACTURE, TRANSPORT, ASSEMBLY AND DISASSEMBLY?

Credit: ITAC UofU

IS THE DESIGN OF THE PROJECT DEVELOPED SO THAT WORK IS STRUCTURED FOR WHAT IS DONE ONSITE AND WHAT IS DONE OFFSITE?

Credit: ITAC UofU

IS DETAILING DEVELOPED IN COLLABORATION WITH THE DESIGN TEAM, GENERAL CONTRACTOR, FABRICATOR AND INSTALLER?

Credit: ITAC UofU

ARE DESIGN CHANGES REDUCED AND ARE ORDERS PLACED IN A SHORT TIME FRAME TO REDUCE COST?

Credit: ITAC UofU

IS FABRICATION PERFORMED WITH PROTOTYPES AND LEAD TIMES REDUCED IN COORDINATION WITH THE PROJECT TEAM?

Credit: ITAC UofU

ARE SITE DELIVERIES MADE JUST-IN-TIME, LOADED AND DELIVERED TO MINIMIZE HANDLING?

Credit: ITAC UofU

ARE ASSEMBLY OPERATIONS DESIGNED COLLABORATIVELY AS CONTINUOUS FLOWS TO ENSURE SAFETY, QUALITY, TIME, AND COST PARAMETERS ARE MET?

Credit: ITAC UofU

Source: ITAC UofU

TYPE

PLACE

Duration Unique Procurement Repetition

TEAM

McGraw Hill 2011


OFF-SITE BENEFITS

Credit: NIBS OSCC

Source: R.E.Smith Prefab Architecture (Wiley, 2010)

!$29,822!!!$74,245!!

!$134,030!!

!$335,074!!

!$-!!

!$50,000!!

!$100,000!!

!$150,000!!

!$200,000!!

!$250,000!!

!$300,000!!

!$350,000!!

!$400,000!!

!$450,000!!

0%!REDUCTION! 25%! 50%!

36,000!SF!CHARTER!SCHOOL-!$7!M!

CONSTRUCTION!INTEREST!SAVINGS! INCOME!GENERATION!

!$52,214!! !$78,147!!

!$293,333!!

!$440,000!!

!$-!!

!$100,000!!

!$200,000!!

!$300,000!!

!$400,000!!

!$500,000!!

!$600,000!!

0%!REDUCTION! 25%! 50%!

40,000!SF!OFFICE!SPACE!-!$7.66!M!


!$5,187!! !$10,350!!

!$29,333!!

!$58,667!!

!$-!!

!$10,000!!

!$20,000!!

!$30,000!!

!$40,000!!

!$50,000!!

!$60,000!!

!$70,000!!

!$80,000!!

0%!REDUCTION! 25%! 50%!

8,000!SF!RETAIL!SPACE!-!$1.55!M!


SCHEDULE ROI

Credit: ITAC UofU

Site

SS6.1

H2O Energy

EA1

Resource

MR2.1, 2.2, 4.1, 4.2, 5.1, 5.2, 6, 7

Air

EQQ 1,2,3, 4

habitat

Credit: ITAC UofU

Source: Quale et al. Construc0on Mabers: Comparing Environmental Impacts of Building Modular and Conven0onal Homes in the United States. JIE 2012.

TEAM

TYPE

PLACE

Geography Manufacture Material Install Labor Regulation


NIBS Offsite Construction Council

Ryan Smith, Chair, University of Utah Sue Klawans, Vice-Chair, Gilbane Building Co. Tom Hardiman, Secretary, Modular Building Institute Martin Anderson, American Institute of Steel Construction Ian Peter Atkins, KPF Architects John Erb, Deluxe Building Systems Brad Guy, Catholic University of America George Lea, Army Corp of Engineers Dan Nyce, Oldcastle Allen Post, Perkins and Will Architects RJ Reed, Whiting Turner Construction Laurie Robert, NRB Inc. Greg Rohr, PIVOTek Stacy Scopano, Autodesk Staff: Ryan Colker, JD, NIBS

www.nibs.org www.wbdg.org •  Whole Building Design Guide •  Core Glossary of Terms •  Case Studies •  Metrics Survey •  How-To Guide •  Research Needs Assessment

Questions? This concludes The American Institute of Architects Continuing Education Systems Course

OFF-SITE

Ryan E. Smith, Associate Professor Director ITAC, University of Utah

STUDIES

Disclaimer: This presenta1on was developed by a third party and is not funded by WoodWorks or the So=wood Lumber Board.

PREFABRICATION - WoodWorks · construction or any method or manner of handling, using, ... solid...

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