1 Modular Practices & Prefabrication: Yesterday, Today & Tomorrow Bernie Sublette Vice President AECOM Hunt Don Page Director of Engineering Good Samaritan Hospital Kurt Stahl Chief Operating Officer Wurster Construction Speaker Introductions November 8th, 2021
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1) Respondents Agree Prefab & Modular Provide Significant Benefits
2) Users Forecasting Expanded Use of Both Approaches Over The Coming Years
3) More Data Available Now to Validate The Processes
4) Owners More Comfortable With The Process & Outcomes
5) Industry Has More Resources to Support Prefab & Modular
SmartMarket Report - Summary of Findings
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
Vertical MEP Chase by Brandt Mechanical, UHS Hospital – San Antonio, TX
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1) An Introduction For Architects, 41 Pages
2) AIA Publication
3) Historical & Educational Data
4) Case Studies
5) Also Identifies The Barriers & Benefits
6) (3) Phases of the Modular Journey:
a) Pre-Design
b) Design
c) Post Design
7) Glimpse Into The Future
Primary Resource 2 – Design Industry Guidance/Educationhttps://content.aia.org/sites/default/files/2019-03/Materials_Practice_Guide_Modular_Construction.pdf
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What – What is Prefabrication & What is Modular Construction?
Why – Why Should We Be Considering Prefabrication & Modular Construction?
How – How Do We Plan, Design, Procure & Install?
Who – Who Are The Players?
Where – Where Does Prefabrication & Modular Construction Occur?When – Expected Milestones & Timing of Key Events?
OR Ceiling System by Flexible OR Solutions – Dripping Springs, TX
Presentation Format
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Prefab in Healthcare Setting – Penn First Pavilion (YouTube)
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WHAT
Prefabricated Bathroom Pod & Headwall for hospital patient room – Atrium Health, Charlotte, NC
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Design for Manufacture and Assembly
1) Should be Initial Approach to Design
2) Two Methodologies
• Designing for Ease of Manufacture
• Designing for Ease of Assembly
3) Facilitates Duplication/Repetition of The Product
4) Reduces Cost of Manufacturing & Assembly
5) Drives Out Waste or Inefficiency
6) Lean Practice
DfMA Process Defined
BIM Model - Prefabricated Bathroom Pod
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1 - Volumetric - 3 Dimensional Units of Enclosed Space
a) Bathroom Pods, Patient Rooms, Elevator Sections,
Stair Cores, Skid Mounted MEP Units
b) Can be Structural or Non-Structural (i.e.BLOX, Modular
Design +, DBC)
c) Recent Years Structures Have Exceeded 10 Stories
d) Stack Like Legos
2 - Non-Volumetric
a) Sections of Flat Building Façade & Cladding
b) Wall Panels & Interior Partitions (i.e.DIRTT, Falk Built)
Volumetric Definitions – (2) Types
Volumetric Construction
Non-Volumetric Construction
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1) Multi-Trade Prefabrication (left image)
a) Work Out of a Common Shop
b) Unit is Framed, Sheathed, MEP / FP / LV, Med
Gas, Insulation, Etc.
2) Single-Trade Prefabrication (right image)
a) Curtain Wall - Example Far Right This Page
b) Pre-Glazed Units Ganged Together, Hoisted Into
Place
Multi-Trade - Utility Tunnel MEP Racks Lowered Into Place at UTSW Dallas
Single Trade - Unitized Curtain Wall System
Trade Involvement
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Most Likely Type - High Frequency (All Respondents)
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
643
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Most Frequency of Prefab By Type (Per Respondents)
GC’s / CM’s
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
Trades
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Why Healthcare? Many Possibilities
Curtain Wall
Stair Core
Patient Bathrooms
Flex Headwall
Clinical/Exam
Room
OR Ceiling System
Uber Modules MEP Corridor Racks
OR Wall System Utility Tunnel Racks Clinical/Exam
Room
Exterior Facade
Interior Wall Systems
Med Gas Manifolds
MEP Chases
Scrub Sink Module
Others:
Emergency Dept, Nurse
Observation Units,
MDF’S, Elec. Rooms,
Elevator Cores, Etc.
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Respondents Forecast For Increased Use of Prefab/Modular
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
1 2 3 4
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WHY
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1) Facing Shortage of Skilled Labor (Probably #1 Reason)
2) Need to Reduce Cost of Construction
3) Speed To Market - Shortened Durations
4) Advancements in Technology - BIM, CAD/CAM/CNC*
5) Ability to Improve Safety & Lessen Risk
6) Able to Produce Higher Quality Results
7) Seeing Exponential Productivity Gains
Headwalls Being Prefabricated on 12th Floor Shell Space at UTSW Dallas
*CNC (or Computer Numerical Control) Precision Machining is a widely used technique for producing a variety of complex parts and components with a high degree of accuracy.
Factors Driving The Use of Prefab
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1) Construction Industry is Projected to Grow 12% By 2026
2) BLS Says “Faster Than Average Job Growth”
3) Normally Great News, But …….
4) Detrimental Imbalance – Worker Demand Versus Available Labor Supply
5) 78% of Construction Companies Struggle to Fill Salaried & Craft Positions
6) Skilled Workers Retiring Out of Their Positions (Boomers)
7) Young Talent Not Available to Step up in Their Stead
8) Over The Past Decade, Construction Companies Have Struggled With
Developing Interest in Trade Work
Shortage of Skilled Labor – National Crisis
“White Paper – Modular Building Institute (MBI)”
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1) Concern Over Shortage - Top Driver For Prefab Per GC’s/CM’s
2) Focus is on Modular Construction’s to Combat Workforce Shortages
3) Less Challenges Now - Prefab Industry is Maturing Rapidly
4) Moving in This Direction for Survival … Major Construction Companies &
Design Firms Are Buying Prefabrication Shops & Modular Building Plants
5) Workforce Shortages Are Counterproductive to The “Need for Speed”
Shortage of Skilled Labor – National Crisis
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
“I feel the need, the need for speed”
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1) Using Precision Tools – BIM, CAD/CAM, CNC, Jigs, Lifts, Conveyors, etc.
2) Building & Storing Product in an Enclosed Facility
3) Work is Protected From Elements
4) Less Exposure to Weather, Less Moisture Related Damage
5) Result: Increased Durability of Project Components
Quality Gains
BLOX Manufacturing Plant – Birmingham, AL
Digital Building Components – Phoenix, AZ
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Productivity Per Industry
Charting productivity 1950-2012
manufacturing
construction
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1) Space Designed for Ideal Conditions to Manufacture2) No Impact From Adverse Weather
3) Precise/Advanced Tools & Machinery
4) Crew Workday (Hours) is Longer Than The Field
5) Less People - Same Amount of Work
6) Mistakes in Field Vs. Mistake in Shop
7) Inspections in Shop Vs. in Field
Improved Productivity
Exterior Wall Panel Receiving a Window at Baker Triangle Prefab Shop – Dallas, TX
Unknown Construction Worker That Cannot Feel his Fingers – Somewhere, USA
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1) Controlled Setting, No Hazards of Extreme Weather
2) Noise & Air Quality Improved
3) Much Less Ladder & Scaffolding Work
4) Lighting is Better
5) Cleanliness Better Than Jobsite
6) Rates for Injuries Substantially Lower In Manufacturing
Setting (U.S. Dept. of Labor) Than in the Field
Enhanced Safety
Prefabricated Utility Bridge - Good Samaritan Hospital Vincennes, IN
Acme Prefab Shop – No Longer in Business
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1) Concurrent Workflows for Off
Site & On-Site Activities
2) Build Prefab While Foundations
Are Being Constructed
3) Supply Chains – Distinct From
Field
4) Added Certainty is Better Than
Cost Savings
Shortened Schedule
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Impact of Prefab From 3 Points of View –
Winner: Productivity
Architects GC’s / CM’s Trades
1 2 3
“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”
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HOW
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1) Connections to On-Site Elements & Module-to-Module
2) Connections to Foundations, Structural Elements,
Elevators & Stair Cores
3) Evaluation of Prefab Components :
• Thermal Performance
• Acoustics
• Water Intrusion (During Construction)
• Fire/Smoke Penetration
• Exterior Façade Interface
Prefab Connections/Demarc’s
Corridor MEP Rack Installed & Ready for Rated Wall to be Installed Beneath & Ready for Connections to Traditional Jobsite Installed MEP Components
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Procure Modular Manufacturer Services
1) Joint Effort
a) Owner Issues P.O. FOB Jobsite, Assigns Install to CM
b) CM Has Skin in Game
c) CM Installs With Local Forces (Possibly XBE)
d) Supervision/Training by Vendor
2) All CM Effort
a) CM Issues P.O. FOB Jobsiteb) Installs With Local Forces as Depicted Abovec) Probably the Preferred Method
3) Don’t Let Contract Tie Your Hands
Engage Modular Manufacturer
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1) Establish Coordination During Design
2) Spec Section 13 Prefab Modular Bathrooms
3) Develop a Detailed Responsibility Matrix
(See Example This Page)
4) Matrix to be Included in RFP
RFP Scope of Work Coordination
BATHROOM PODSResponsibility Matrix
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Project Delivery Method
1) Traditional Design/Bid/Build Model Not Well Suited to Prefab
2) Need Collaborative & Iterative Delivery Method (CHI Baylor)
3) Like Design Assist, Design/Build & IPD (Integrated Project Delivery)
4) Engagement EARLY in Design Process
5) Early & Real Costing By Having MM Onboard Early
6) MM Able to Provide Guidance & Coordination More Effectively
1) Regardless of Delivery Method, Early Involvement of Modular
Manufacturer is Crucial
Prefabricated MEP Corridor Racks Installation Mount Carmel Hospital- Columbus, OH
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1) AIA Document – Defines Responsibilities
2) Detailed Scope of Work Checklist (See Example at Right)
3) Communicates Tolerance & Interface Details For
Connections On-Site
Prefab Design Coordination Check List
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1) Small But Critical Component in Process 2) High Degree of Confidence in Field Layout (Tremble, Etc.)3) Goal - Increase Shop Hours & Minimize Field Hours4) Precise Information to Shop Personnel (Spool Drawings,
Labels. Etc.)
5) Robust Virtual & Field Trade Coordination is Mandatory
BIM (Leveraging Technology)
Prefabricated Bathroom Pod at UTSW Dallas
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Maintaining Compliance
1) Determine Local Permitting Requirements EARLY
2) Must Meet Local Codes Regardless of Manufacturing Location
3) Most States Have Specific Modular Building Program, Some Don’t – Indiana Does
4) State Building Program – 1) Approval of Modular Manufacturer, 2) QA/QC, 3) Plans
5) Inspections Will Be Req’d Both at Shop & On-Site When Connecting
6) State-Licensed Third-Party Design Agency Conducts Off Site Inspections