Prefab Architecture: A Guide to Modular Design and Construction

Prefab Architecture: A Guide to Modular Design and ConstructionSMITH
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“Prefab Architecture . . . is beyond theory, and beyond most of what we think we know about pods, containers, mods, and joints. This book is more than ‘Prefabrication 101.’ It is the Joy of Cooking writ large for the architecture and construction industries.”
—From the Foreword by James Timberlake, FAIA
THE DEFINITIVE REFERENCE ON PREFAB ARCHITECTURE FOR ARCHITECTS AND CONSTRUCTION PROFESSIONALS
Written for architects and related design and construction professionals, Prefab Architecture is a guide to off-site construction, presenting the opportunities and challenges associated with
designing and building with components, panels, and modules. It presents the drawbacks of building in situ (on-site) and demonstrates why prefabrication is the smarter choice for better integration of products and processes, more effi cient delivery, and realizing more value in project life cycles. In addition, Prefab Architecture provides:
A selected history of prefabrication from the Industrial Revolution to current computer numerical control, and a theory of production from integrated processes to lean manufacturing
Coverage on the tradeoffs of off-site fabrication including scope, schedule, and cost with the associated principles of labor, risk, and quality
Up-to-date products featuring examples of prefabricated structure, enclosure, service, and interior building systems
Documentation on the constraints and execution of manufacturing, factory production, transportation, and assembly
Dozens of recent examples of prefab projects by contemporary architects and fabricators including KieranTimberlake, SHoP Architects, Offi ce dA, Michelle Kaufmann, and many others
In Prefab Architecture, the fresh approaches toward creating buildings that accurately convey mature and expanded green building methodologies make this book an important voice for adopting change in a construction industry entrenched in traditions of the past.
RYAN E. SMITH is Director of the Integrated Technology in Architecture Center (I TAC), an interdisciplinary research consortium at the University of Utah College of Architecture + Planning in Salt Lake City, Utah (www.itac.utah.edu). Smith’s research and teaching focuses on promoting integration that leads to sustainable and lean design and construction practice.
Architecture/Construction
John Wiley & Sons, Inc.
PREFAB ARCHITECTURE
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Library of Congress Cataloging-in-Publication Data:
Smith, Ryan E. Prefab architecture : a guide to modular design and construction / Ryan E. Smith ; foreword by James Timberlake. p. cm. Includes bibliographical references and index. ISBN 978-0-470-27561-0 (cloth : alk. paper); ISBN 978-0-470-88046-3 (ebk); ISBN 978-0-470-88043-2 (ebk); ISBN 978-0-470-88044-9 (ebk); ISBN 978-0-470-95030-2 (ebk); ISBN 978-0-470-95055-5 1. Buildings, Prefabricated. I. Title. II. Title: Guide for architects and construction professionals. NA8480.S66 2011 721’.04497—dc22
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Introduction xi
Acknowledgments xv
PART II—APPLICATION 75
Chapter 4 Principles 77
Chapter 5 Fundamentals 99
Chapter 6 Elements 127
Chapter 7 Assembly 181
Chapter 8 Sustainability 217
Chapter 9 Housing 251
Chapter 10 Commercial 295
PART IV—CONCLUSION 333
Chapter 11 Conclusion 335
v i i
FOREWORD
Since the beginning of time, buildings have been executed in situ, on-site. From the fi rst primi- tive hut through the pyramids, ancient Rome and Greece, all of our modern cities and great cultures have been served by men and women working the trenches of construction stick upon stick, brick against brick, element by element. As wealth began to afford more and more manual labor and greater craftsmanship, and time was defi ned as “forever,” the results were profound: the greatest, largest, most opulently fi nished structures ever. Improving quality meant putting more labor on the problem. Increasing scope meant putting more labor on the problem. We reaped the benefi ts of inexpensive la- bor and massive amounts of time for large program scopes and the highest quality until the turn of the twentieth century.
For the last 100 years, as the economy has become more sophisticated and global, one equation has governed construction: Q (quality) x T (time) = S (scope) x C (cost). No matter which variable is defi ned as paramount to a project—quality, time, scope, or cost—the other variables must stay in balance. Want less time with a fast track schedule? Then give up quality, spend more money, or reduce the scope. Want a lower budget? Manage costs, reduce quality, and reduce scope. Want higher quality? Increase the budget proportional to your scope and likely increase time. Project after project around the globe has been dominated by this equation.
The historical chronicles of prefabrication are well and widely published, most notably in 2008 by Barry Bergdoll in his catalogue for Home Delivery: Fabricating the Modern Dwelling, The Museum of Modern Art’s exhibit on the historical and contem- porary signifi cance of factory-produced architecture. Prefabrication in its earliest form was less about ad- dressing quality and time or managing scope and costs—let alone about applying an environmental ethic—than it was about a fascination with indus- trial commoditization, production, and replication. Focused generally on housing typologies, the scal- ability of offsite fabrication was more focused on meeting a theoretical need for a booming housing market than it was on the integration of systems, ma- terials, and production with the possibility for mass- customization.
With a lack of focus on integration, early attempts at factory production collapsed without fi rm ground up foundations in place. As George Romney, the Housing and Urban Development Department Secretary and refugee of the automotive industry learned in the 1970s, the “top down” strategy of forcing the con- struction industry to adopt offsite construction while encouraging its promise was quite damaging. The lack of integration tools available to the industry, and the post-war rollercoaster economy conspired to doom the effort. People were left bankrupt, de- moralized, and discouraged from ever attempting to change an industry so entrenched. Since that initial
Quality Assurance, Quality Control
James Timberlake, FAIA, KieranTimberlake
v i i i FOREWORD
effort to change the construction industry, we have seen a steady decline in the productivity of the con- struction industry, leaving architects to assume the burden of change.
What has changed in the world to make prefabrica- tion viable today?
First, other industries have changed the way they work and provide products. As Stephen Kieran and I chronicled in Refabricating Architecture, the auto- mobile, shipbuilding, and aerospace industries have remade themselves completely, sometimes twice over, since 1995. Their production methods are leaner, more time and material effi cient, and more worker friendly. Their output range extends from a fully mass-customized product (automobiles) to a nearly fully customized one-off product (ships). The scale of these products on average also exceeds the complexity and scale of almost anything produced in architecture. Arguably, a ship, plane, or car, all of which have to move and carry occupants and prod- ucts safely, day in and day out, are more complex overall than many of the buildings the construction industry produces. Simply, the construction industry needs to deliver a product that meets the require- ments of design, on budget, on time, without falling down or leaking. It often fails at this task.
Second, the critical difference is that the air, ship, and auto industries integrate—both at the source of inspi- ration and at the source of supply. They have a cap- tive supply chain and during the past two decades have integrated, redefi ned, and then reintegrated leaner supply chains and products. Effi ciency begins at inception and is consistently interpreted and reinte- grated throughout the design and production cycles. The design side of these industries is also integrat- ed—usually with captive design divisions informing
and collaborating with production teams, allowing for continuous evaluation and improvement.
By contrast, the supply chain for the architecture, construction, and building product manufacturing industries is extended and fragmented. Architects often rely on uncoordinated and poorly integrated product supply references, such as the Sweets Catalog, to research, understand, and specify prod- ucts. Those products are often placed into docu- ments and projects as open choices to be further whittled down by the construction bidding and pro- curement process. From there, a vast array of mostly uncoordinated products is destined for an onsite construction project with the workforce relegated to coordinating, fi tting, and integrating these products into a coherent whole. This process is pure chaos, even under the best and most organized conditions. Often, a vast number of trades converge on a sin- gle point of fi nish within a project—bathrooms and kitchens often the most cited example—where they cannot all work, let alone fi t, at one time. Yet each is under great pressure to complete the work not just on time, but ahead of time. Add to this chaos unpre- dictable weather or work conditions, outside of the normative comfort zones for a normal workplace, and the stress of completing the work increases with the likelihood of diminishing the quality that most architects and clients demand.
Yet architects’ tools to integrate have changed. The architecture profession has embraced three-dimen- sional building information modeling and produc- tion tools. We are now able to visualize and correct “busts” before they are built. We have better commu- nication tools, some of which have been embraced by the construction industry, such as online docu- ment and project management software, enabling real-time sharing of designs, information, and results.
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We are now capable of sending a fully visualized, and virtually formed, model to a production line, bypass- ing the document interpretation phase, with all of its back and forth checking, redrawing, and margin for additional errors and omissions, ultimately improving the quality of the fi nal product.
Third, however slowly, the environmental ethic of the architecture profession and the construction industry has begun to change. Onsite construction has been estimated to waste up to 40% of all new products brought to site. Imagine a clean, 4 x 8 foot sheet of brand new drywall. Now imagine approximately 2 feet square of each and every sheet brought to the site ending up in a dumpster and headed to a landfi ll. Add to that load after load of metal stud ends, wires, components, broken glass, aluminum, concrete block, and brick and it adds up to a small building’s worth of components and raw materials wasted each and every time we construct a building. The industry, the profession, and the world can no longer tolerate that sort of waste, let alone continue to absorb the economic impact of it.
Integration modeling, the backbone of offsite fabri- cation and manufacturing, leans the product supply chain, helps architects and constructors manage the amount of materials needed and allows for a positive repurposing of the left over materials. Further, offsite assembly offers the promise of disassembly and re- use. Rather than repurposing a whole building, we might now consider disassembly as a way forward to altogether new re-uses for building materials. The ho- listic integration of sustainable materials helps to pro- duce a greener fi nal product. Rather than haphazard applications of materials and systems in a way that purports to be sustainable—a practice I often refer to as “green bling”—offsite construction and manufac- turing offers what we might call “total sustainability,”
broadly defi ned as being 100% compliant through- out all building materials and systems in an economic and useful manner. Offsite construction presents the opportunity for this high level of compliance through integration, document and supply controls, and ma- terial management.
In addition, despite incredible improvements in workplace safety, the construction site remains a dangerous place, fraught with potential accidents, and generally exclusive of women. The construction industry must become leaner, safer, and broaden its workforce in order to remain safe, economically competitive, and relevant. A more inclusive work- place with real safety measures, and eliminating the factor of weather by building indoors rather than outdoors for the vast majority of the project, is also a long-term sustainable measure. It ensures greater productivity, the potential for growth, and the broadening of a workforce and workplace that is unlimited.
Ryan Smith has demonstrated with numerous ex- amples of experimentation, collaboration, and hard work by countless individuals in his book the premise that “something has to precede something else.” Prefab Architecture is a fi rst read—the “pre” in whichever mode of fabrication that an architect and client choose to embrace. This book pro- vides a guide to frontloading a project, and in turn, a means of changing our economy, changing the way we think about architecture and design, and changing the affordability and the quality of what is produced. Call it “nextgen” construction logic. It is beyond theory, and beyond most of what we think we know about pods, containers, mods, and joints. This book is more than “Prefabrication 101.” It is the “Joy of Cooking” writ large for the architecture and construction industries.
FOREWORD ix
x i
INTRODUCTION
Prefab Architecture is intended to reach a wide range of readers, including architects who design detached dwellings, architecture and building technology stu- dents, and researchers and practitioners interested in the application of prefabrication as a production method for building. In addition, readers of maga- zines such as Dwell will be interested in the prefab examples and possibilities.
Prefabrication—often associated with the terms “off- site,” “assembly,” or just simply “fabrication”—can be viewed as stuck in the trenches of nineteenth-cen- tury conventions of standardization and twentieth- century modernism. Common construction means have not changed drastically over the last 80 years. In order for architecture to come into fruition—to ac- tually be built—it takes many years, requires heavy investment, and is fraught with confrontation, value engineering, headaches, and inevitable heartache. This is not to say that new materials and methods of production have not advanced other industries, on the contrary. John Fernandez writes, “It is widely be- lieved that construction is the slowest of all industries of such scale in implementing proven, scientifi cally sound technological innovation.”1 There are many reasons for the lack of innovation in the production of architecture that will be discussed throughout this book. The reality of this lack of building construction innovation must be defi nitively stated as an argument for why prefabrication should be pursued.
As a beginning we need to defi ne what “offsite fab- rication” is and what it is not, to alleviate confusion
on its meaning herein for the reader. Webster says that “prefabricate” means, “to fabricate the parts of at a factory so that construction consists mainly of assembling and uniting standardized parts.”2 This defi nition in the contemporary dictionary has an en- try date of 1932, seemingly not to have changed since. Prefabricate is a transitive verb. The noun “prefabrication” is then the parts that have been produced and then are assembled onsite; but one might wonder why the “pre” in prefabrication. The only explanation is that fabrication was at one time considered something that happened on the site; hence prefabrication meant that there was a body of work that occurred before the actual onsite fabri- cation commenced, or in today’s terms, before as- sembly onsite. Therefore, should prefabrication be called manufacturing? The technology of industri- alization has progressed since 1932, but the word has not, leaving us to continue to say prefabrication when in fact we may mean something very different. The lack of progress in the word usage is an indica- tion of a lack of dialogue concerning construction methods and progress in the construction industry in general.
Prefabrication, however, is a pervasive term and it would be futile to try to debunk it within this context. Suffi ce it to say, throughout this book, the terms “pre- fabrication,” “offsite fabrication,” and “offsite produc- tion” are used interchangeably to mean elements intended for building construction that are produced offsite to a greater degree of fi nish and assembled on- site. The topic of prefabrication for this book is a jump-
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x i i INTRODUCTION
ing-off point to explore many other related aspects of building culture including housing, building technol- ogy, and architectural practice today. The intention in writing this book is to relate the history of industrialized building, the theory of technology in architecture, prin- ciples of industrialized building, classifi cations of in- dustrialized building, products, and how the integrated process can lead to fi nding a greater balance between economy, effi ciency, and aesthetics.
There is a growing interest in the architecture, en- gineering, and construction (AEC) industry in devel- oping approaches to building that allow for greater effi ciency and precision, are environmentally con- scious, make better use of a declining workforce, and provide shorter construction cycles. As an alternative to conventional building practices, there is growing reliance on assembling offsite-manufactured and fabricated components throughout the industry. The expanding middle classes cause increased demand for buildings, from the prosaic to the remarkable, and the working class offers up fewer skilled laborers to produce these buildings. As a result, the construction industry has had to rethink its processes, relying in many cases on technology transfer from the manu- facturing industry. Offsite manufacture and computer numerically controlled digital fabrication toward mass customization have far more relevance to architects today than any of us might have predicted only 10 years ago.
Prefab architecture is not new, and the points in history when it was most relevant often mirrored the circumstances of today. The Crystal Palace of 1851 by Joseph Paxton is cited as one of the earli- est prefabricated buildings (although there are many examples that preceded) whose production also re- fl ected the technological advances and expanding middle classes of nineteenth-century England. This
economic expansion continued throughout the lat- ter half of the nineteenth century, and the need to house the burgeoning middle classes supported a…