Benchmarking best practice in

the offsite sector

Why is the Buildoffsite AccreditationScheme important to the offsiteconstruction industry?The answer is:

� it provides client organisations withgreater confidence of delivery to time,cost and quality through theimplementation of risk management bestpractice

� it provides management andshareholders with the assurance thattheir risk management, competencymanagement and configurationmanagement systems have beenindependently validated as meeting bestpractice with the attendant likelihood ofcostly mistakes minimised

� it represents a key element of theBuildoffsite Property Assurance Schemeand will facilitate a route to market forthe offsite provider with recognition ofthe scheme by all major lendersincluding RBS, Lloyd’s Bank, Santanderand Nationwide, together with RICS andthe valuer community.

HighlightsThe workshop will represent an interactivesession with opportunities for delegatedebate and discussion throughout.

Representatives from accredited offsiteproviders will deliver their perspective ofthe accreditation process – what it meantfor them in terms of investment and therealised added value

What will the participants gain fromattendance?The opportunity to discuss the BuildoffsiteAccreditation Scheme with both theaccrediting body and organisationsaccredited.

You will learn that we do not seek tointroduce new systems and processes butto work with those you have alreadyimplemented to achieve best practice.

The session will cover:

� an overall insight into the scheme, scopeand coverage

� the importance of an integrated riskmanagement system

� how risk management and configurationmanagement processes reduce thelikelihood of costly mistakes

� how an integrated risk managementsystem involves everyone in theorganisation and aligns everyone tocommon aims and goals

� how definitive competency matricesminimise variability of performance

� how the systems required by thescheme encourages communicationbetween members of the supply chain,minimising interface issues.

The use of offsite construction methods is agrowing phenomenon not just in the UK butalso across much of the Globe. Given theincreasingly international nature ofbusiness and the free flow of knowledgeand best practices this is hardly surprisingbut what do we really know about thedevelopment of the offsite market in othercountries?

In the first of a series of articles fromcontributors from around the world thefollowing piece gives a sense of how themarket for offsite is developing in the USand how practice over there compares withpractice over here. Our contributor isJames B. Guthrie, AIA, architect andPresident of the Miletus Group.

James is also an entrepreneur with amission. He has established the MiletusGroup as a designer and manufacturer ofoffsite construction systems. He made thismove from traditional on-site buildingpractices because he was not satisfied withwhat the market had to offer and wanted todevelop better solutions. James is a great

enthusiast for modularbuilding techniques as ameans to achieve realarchitecture. He saysbest results are achievedwhen excellence indesign is close-coupledto expert knowledge ofconstruction practice.James also has a strongcommitment to thedevelopment of skills within his industryand advancing new knowledge. He iscurrently chairman of the US ModularBuilding Institute’s Education Foundation.

A message from America

I visit the UK several times a year onbusiness and also to keep up to date withdevelopments in offsite solutions on yourside of the pond.

People often ask me if the US market foroffsite solutions is more advanced andmore sophisticated than the market in theUK. When they ask this question I get areal sense that the expected response hasto be that in the US we are years ahead ofyou Brits. The fact is that generally we arenot. Indeed in many ways the UK is farahead of us in terms of the range of offsitesolutions offered and which in manymarkets are becoming quite commonplace. Why this should be took me sometime to understand. The US led the waywith the development of modernmanufacturing methods and the move tomass production and construction. Mostpeople are unaware that back in 1931when the Empire State Building wasconstructed that it was, in part,manufactured with large scale structuraland cladding components delivered to siteusing what we would now describe as “justin time” practices. Assembly of large scaleprefabricated components was the onlyway to construct a record breaking buildingin the time and to the budget set by theclient. The construction time wascompressed into just one year and 45 days

February 2011

1

Richard Ogden,Chairman

20

James Guthrie – a man witha mission

Dates: Tuesday 5 April 2011 andWednesday 21 September 2011

Venue: Buildoffsite, Classic House,174–180 Old Street London, EC1V 9BP

Time: 08.30am – 10.00am

Delegate places at this event are free –on a first come first served basis

Presenters: Nick Whitehouse,Buildoffsite, Simon Wood, Britspace andTerry Mundy, Lloyds Register

To register for this workshop contact AnnaWhiting, Buildoffsite on email:anna.whiting@buildoffsite.com or tel:0207 549 3306.

….. best resultsare achieved

whenexcellence in

design isclose-coupled

to expertknowledge ofconstruction

practice.

www.buildoffsite.com www.buildoffsite.com

R&D breakfast briefing

Maximising R&D tax reliefWe all know that thebusiness environment atthe present time is verychallenging and theconstruction sector isunder particular strain.In these circumstancesno organisation can

afford to waste money or for thatmatter miss out on opportunities to recoverexpenditure where tax credits are available.An obvious concern is that constructionbusinesses should be taking maximumadvantage of the opportunities for R&D taxrelief.

Companies involved in the development ofoff-site solutions and other forms ofinnovation will be investing money inresearch and development but may not bemaximising the benefits available under theUK Tax system. This is your opportunity tofind out if you could be recovering more ofyour investment.

In support of its Members and GuestsBuildoffsite is pleased to host a specialBusiness breakfast briefing on MaximisingR&D tax relief featuring Gareth Edwards ofela. This is your opportunity to find out ifyou could be recovering more of yourinvestment.

Key issues:� exchange up to 24.5 per cent of your

losses for cash

� reclaim your corporation tax, or reducefuture liability

� immediately claim 100 per cent of yourcapital spend against tax

� claim for the last two years

� significantly enhance your existingclaims

� intellectual property – can now claimunder SME scheme even if IP not owned

� qualifying indirect activities – recentHMRC guidance can increase claims

� new minefield – HMRC guidance on“production” activities

� understand how the R&D tax regimeswill change (currently under discussion)

� get tax relief on revenue due to patentedtechnology (current proposal).

To find out more why not join us at ourBuildoffsite business breakfast…

Presented by: Gareth Edwards, ela8

Gareth Edwards is a life-long R&Dprofessional and entrepreneur, withextensive experience of putting togetherand supporting R&D tax relief claims for awide range of companies, frommultinationals to start-ups – gained whilstworking as a Director for the award-winningDeloitte & Touche R&D Tax Services group.He has presented at numerous publicforums on the benefits available, and howto set about claiming. His deep interest andinsight into technology means he can talkeffectively with your technologists, quicklyextracting the scope and basis for yourclaim and presenting this in a way that thetax authorities will understand and accept.

This workshop will feature:

� an introduction to R&D tax relief

� what activities and expenditure can beeligible

� examples of eligible projects

� question and answer.

and the job came in way below budget at$41m. So almost 80 years ago we wereclearly doing something right – somethingthat has worked brilliantly well as asustainable commercial project and as aniconic piece of construction.

The parallel ofwhere theeconomy is todayto how thingswere during theglobalDepression whenthe Empire StateBuilding wasconstructed is notlost on me.Perhaps we needthe stimulus of amajor economicchallenge to getpeople to step upa gear in terms oftheir willingnessto look beyond

the status quo for construction solutionsthat contribute a step-change in value forclients and customers.

The US housing market and markets suchas Canada have always had a very efficientmanufacturing and construction sectorharnessing the flexibility and cost benefitsof timber frame systems. We do of coursegrow a lot of timber in the US and Canada,and have been exploiting wood as aprimary building material since the firstsettlers arrived in the US in the sixteenhundreds. Wood buildings are incrediblypopular with US customers and very fast toconstruct on site from a basic set of factorymade components. In the housing marketthe US is already in large part committed tothe use of offsite solutions whereas for themost part the UK is addicted to new buildhomes mainly constructed using masonry.So the US tradition for timber frame ismatched in the UK by a long establishedtradition of brick and block construction.Both traditions have their establishedsupply chains that, of course, are verycomfortable but which in no way provides

any sort of incentive to spur those involvedto want to change to an alternative. Insteadalternatives such as the employment ofoffsite modular components are viewed asuntested and therefore full of potential risk.

Curiously in the UK I find that people seemvery reluctant – even hostile – to the use ofthe term “prefab” when talking about housebuilding systems. The reason has beenexplained to me but frankly I still don’t getit. In contrast, in the US in some circles totalk about “prefab” when describing newhomes built from a kit of quality factorymade parts is just about the coolest thingyou can do. There are even websitesdevoted to the topic. Who was it who talkedabout “two peoples separated by acommon language……?” The dichotomiesand similarities between the US and UK arereally quite fascinating. I recommend ColinDavies’ History of Prefab as providing asuperb overview of how the offsite sectorhas evolved in both countries.

So what is the UK doing that the US is not.I have been really impressed with the wayin which factory manufactured mechanicaland electrical installations are increasinglybeing used in commercial and officedevelopments and in other highly servicedbuildings such as hospitals. The deliveryand installation of large factory testedinstallations is still relatively unusual in theUS and I can recall a project delivered bySkanska that made use of such factory-made solutions to very good effect onquality and project efficiency and thatattracted some excellent publicity in thetechnical press. What also attractedinterest was Skanska’s establishment of amanufacturing facility alongside theconstruction site. A mobile factory, that wasa clever idea.

2 19

Empire state building

Colin Davies traces the history ofprefabricated buildings from small-scale“prefabs” to the precast concrete masshousing of the 1960s to the present-day.<www.amazon.co.uk/Prefabricated-

Home-Colin-Davies/dp/1861892438>

Date: Wednesday 15 June 2011

Venue: Buildoffsite, Classic House,174–180 Old Street, London EC1V 9BP

Time: 09.00am – 10.00am (registrationand refreshments from 08.30am)

Reserving your place: a notional chargeof £50 +VAT is payable for each delegateplace to cover administration costs. Thereis no charge for Members of Buildoffsite.

Those wishing to book for this briefingshould contact Anna Whiting, Buildoffsiteon: anna.whiting@buildoffsite.com or tel:0207 539 3306.

www.buildoffsite.com www.buildoffsite.com

Use of modular wiring systems inconstruction is something that although Ibelieve started off in the US has been takenforward in the UK as a technique for fasttrack installation of factory manufacturedand tested components. Certainly there is adiscipline involved in the installation of suchsystems but that seems to me to be a goodthing. There is also the point that using afactory made solution minimises materialwaste and also minimises the amount oflabour and supervision required on site,with the opportunity for a major uptick inquality. Adopting within construction thosepractices that are common place in othermanufacturing sectors seems to me to bean absolute “no brainer” and I really do findit frustrating that the US is not making moreuse of the practice.

In both markets there is increasing use ofpods and modular systems. In the UK youhave some really good manufacturers whoare producing quality product for a numberof market sectors where speed ofconstruction on site and an assurance ofbuild quality, delivery and price is absolutelyessential. I couldn’t help but notice that thehotel room I stayed in when I last visitedthe UK had been made in a factory... themajor tell tale was the fact that the serviceconnections had been designed to enablesimplicity of installation and connection andoh yes – the standard of finish was superb.

Helping clients to understand the businesscase for choosing an offsite constructionsolution is I suspect somewhat simpler inthe US where the client is likely to want tofocus on what we call the “financial proforma”. Put simply this involves us in beingable to give the client an absoluteassurance that by adopting offsiteconstruction solutions he is buying a fixedprice, certainty as to quality and a fixedconstruction time – no ifs and no buts. Theclient will understand precisely that they areassured that from a specified date, the

building will be ready to generate revenueand this certainty is then built into thefinancial appraisal of construction system.Clients are most unlikely to have this levelof certainty if they select any other form ofconstruction.

One very significant issue that requiresmuch more attention in both the US and theUK is the need for our workforce to betrained in the new skills and practicesneeded to get the most out of thetechnology advances possible through theincreased use of offsite construction. Forexample during their professional trainingyoung architects are taught very little ifanything about the integration of offsitecomponents with in situ constructionmethods. They are taught very little aboutdesigning for assembly and with greatregret I suspect that their training does notchallenge them to think of themselves asan integral and integrated member of theconstruction team. In my view this is amajor gap in US professional trainingpractices and it is one that the MBIEducation Foundation is seeking toaddress. I believe that much the samesituation applies in the UK. Perhaps this isan effort that would benefit from cross-county collaboration.

A development that is having a real impacton design and construction practice in boththe UK and the US is environmentallegislation and the drive for increasedsustainability. Perhaps the biggestdifference in approach is that in the US wehave an incredible number of differentregulatory systems that dictate minimumlevels of building performance dependingon the State and County Codes. At least inthe UK your regulatory systems are for themost part set nationally.

Both in the UK and in the US the drive is onfor the design of buildings and the buildingprocess to become much more efficient.The regulatory requirements and therequirements of leading clients will requireincreased efficiency in the form of energyrequired to run buildings. Moreover,economic factors will require more efficient

the speed of construction on site. Thisenables Tesco to be faster to market and toopen the doors of a new store to ourcustomers more quickly.”

As an eco-store, the new Southam schemehas a number of sustainability features toreduce its carbon footprint, including:

� roof-mounted photovoltaic panels togenerate electricity

� a high level of glazing to one elevationfor natural light

� sun pipes to the offices and toilets

� rainwater harvesting

� a lobby area to the main entrance withsliding doors to reduce heat loss

� timber cladding from sustainable sources

� mixed mode ventilation

� air scoops for additional ventilation.

The store design also includes back-of-house, staff facilities and officeaccommodation on the first floor, and hasconcrete floors with terrazzo tiling.

Yorkon has worked with Tesco for the past10 years, delivering around 200 projects,including more than 170 Expressconvenience and petrol filling station storesin the UK and Ireland, and is the marketleader in off-site construction solutions forthe retail sector.

Buildoffsite events

Buildoffsite breakfast briefings

Delivering enhanced client value:designing for manufacture andassembly

Context:Clients are looking to their advisers andsuppliers for fresh ideas that will helpdeliver the quality and sustainable buildingsthey require but at a significantly lowerprice and with assured delivery times.

This is a significant challenge and it isentirely likely that if the industry is to rise tothe challenge it will need to adopt newways of working collaboratively.

The practice of designing for manufactureand assembly has been adopted by otherindustries as a proven technique to ensureeffective and informed communication andcollaboration between those developing thedesign and those who will deliver thevision.

Designing for manufacture and assemblydoes not compromise the ability ofdesigners to demonstrate design flair andinnovation. However, it does require themand other members of the professionalteam to be prepared to be prepared to workmore closely with constructors andsuppliers to establish the optimum methodsto deliver the client’s vision whilstminimising risk.

The breakfast briefing:The breakfast briefing will featurepresentations from forward thinkingarchitects, constructors and suppliers onhow they are applying the principles ofdesigning for manufacture and assembly inpractice and the benefits for all that haveemerged. The speakers will be:

� Martyn Wood of Bryden WoodAssociates

� Anna Winstanley of Laing O’Rourke.

318

…. factory manufactured mechanical andelectrical installations are increasingly

being used in commercial andoffice developments

Date: Wednesday 9 March 2011

Venue: Buildoffsite, Classic House,174–180 Old Street, London EC1V 9BP

Time: 08.30am – 10.30am

Reserving your place: attending thisbreakfast briefing is free of charge forBuildoffsite Members. Non-members mayattend but a fee of £50 +VAT will apply.

Those wishing to book for this briefingshould contact Anna Whiting, Buildoffsiteon: anna.whiting@buildoffsite.com or tel:0207 539 3306.

www.buildoffsite.com www.buildoffsite.com

European Hotel Brand of the

Year Award

Gateway Pods Limited, EuropeanHotel Brand of the Year

The design of a new brandprototype Holiday InnExpress for IntercontinentalHotels Group has won theprestigious Hotel Brand ofthe Year Award at theEuropean Hotel DesignAwards 2010.

ICA Architects designed the new HolidayInn Express bedroom suite, bringing inpods experts Gateway Pods to design andmanufacture the new bathroom. ICAcollected the award at The Sleep Event inLondon on behalf of the world renownedHotel group.

Using bathroom pods in hotel projects notonly saves the client time, but also reduceson site trades and waste with the certaintyof a guaranteed cost. Gateway Pods haspartnered with IHG Hotels in the supply ofhigh quality bathroom pods for over 12years.

Up to 10 Holiday Inn Express hotelsthroughout the UK have now been builtusing the award winning hotel room andbathroom design.

Yorkon builds UK’s largest

modular supermarket – an eco-

store for Tesco

Award-winning off-sitespecialist, Yorkon, hascompleted the UK’slargest retail project to bebuilt using modularconstruction – a new eco-store for Tesco atSoutham in Warwickshire.

Working closely with main contractors RGCarter, the Yorkon off-site approachreduced the build programme to increasethe number of trading weeks by eight to thebenefit of Tesco and its customers. Thearchitects for the project were the SaundersPartnership.

The scheme is the first application of a newmodular store design, which provides20,000 sqft of retail space, and hasuninterrupted spans for the sales areas of28m, which are unprecedented in themodular industry. This was achieved byreducing internal columns by 50 per cent.

In order to meet the deadline for the storeopening, 24-hour factory shifts wereemployed at the Yorkon production centrein York to manufacture and partially fit outthe 70 steel-framed store modules, and thecranage phase included both weekend andnight working.

Commenting on the project, LorraineO’Sullivan, Development Manager at Tesco,said: “From a customer experienceperspective, you cannot tell this is a modularbuilding. The over-cladding has been veryeffective and customers have been verycomplimentary about the new store.”

“Off-site construction allows more work tobe carried out in a manufacturingenvironment, improving both quality and

construction processes in order to bringdown costs and to deliver improved valuefor clients and customers. Certainly theUK’s regulations are well ahead of wherethings are in the US but we will catch upquickly just as you have been catching upwith leading EU and Scandinavian practice.

I believe that these developments and thedemands of the market place are going toserve as a real stimulus to the offsite sectorand it will make no material difference ifyour preferred material is timber, steel,concrete, a composite or more likely acombination of all of these. The ability toconstruct building components that willdeliver a high quality performance is alwaysgoing to be that bit more straightforward inthe controlled environment of a factory ascompared to a temporary construction site.Reducing levels of waste is also mucheasier to manage in a factory than on aconstruction site.

Improvingproductivity canreally only betackled by carryingout as muchconstruction as

possible away from the construction site. Ihave absolutely no doubt that the future ofconstruction is going to be offsite and incase you have any doubts about mycommitment just bear in mind that I am soconfident that I bought the company.

I am really pleased to have developedcontacts with the UK’s Buildoffsiteorganisations and to share ideas andlearning. In the US we don’t yet have theequivalent of a Buildoffsite, in that ourvarious industries remain silo’d, but we areworking on greater knowledge sharing andintegration to expand the idea of offsite toall sectors.

New member

ISG has joinedBuildoffsite as itrecognises thecontinuing importance ofoff site techniques indriving efficiencies andsustainability throughoutthe construction

process. Buildoffsite not only bringstogether a host of complementaryorganisations to share and develop bestpractice within the industry but also acts asa catalyst for future innovations andinitiatives within this dynamic sector. ISG isdelighted to add its support andexperiences, whilst positively contributingtowards the promotion and widerunderstanding of off site techniques acrossthe construction industry.

ISG is an innovative business and earlyadopter of off site technology across itsprojects within the UK and internationally.With over 2,000 staff, 28 offices and aturnover approaching £1bn, the businessworks with public and private owners,developers and occupiers across a broadrange of industry sectors. Within the UK,ISG focuses on construction, fit out andfood retail solutions, with a portfolio thatincludes numerous FTSE 100 companies,leading supermarkets, governmentdepartments and social housingorganisations. Internationally, ISG has astrong presence in mainland Europe, Asiaand the Middle East, and delivers high-quality project management and fit outservices for its multi-national client base.

4 17

For more information on ISG visit:

www.isgplc.com

….. reducing levelsof waste is much

easier to manage ina factory than on aconstruction site

…we don’t yet have the equivalent of aBuildoffsite but we are working on greater

knowledge sharing and integration.

For more information on the Miletus Group

visit: www.miletusgroup.com

To view a video of the new store and its

construction go to:

www.yorkon.info/tescosoutham

www.buildoffsite.com www.buildoffsite.com

One bedroom apartments, were selfcontained in one complete module, with anexternal walkway constructed for access.Due to the nature of the site, one elevationwas tapered and as a consequenceindividual modules were designed toprovide the required façade. Our client’saspirations were to achieve EcoHomesVery Good Standard. A range of measureswere employed to achieve this including:

� 33% improvement on U-values aboveBuilding Regulations

� 650 sq m of green roof and 60 m sq ofbrown roof

� low voltage lighting within apartmentsand compact downlighters in publicareas

� FSC timber procured (Caledonian hasfull FSC certification)

� Caledonian modular constructionelements have Green Guide A & Bratings

� home office provision

� low ozone depleting materials, which arestandard within the modular construction

� a range of external measures includingrecycling provision, rainwater harvesting,easy access to shops and the localtransport network.

Teaming up with Tesco

We are delighted to announce that Tescohas chosen to partner with Britspace ontheir new store roll out programme for2010/2011. This contract requiresmanufacturing of a new hybrid productcalled “podular”.

Retail Director Paul Bonaccorsi takes upthe story: “When we looked at Tesco’srequirements for back of house units suchas the managers offices, staff and customerWC’s, staff changing rooms, cash officesetc we developed a new product that wasrobust with a limited floor depth, the resultwas a hybrid of modular building andbathroom pods, contributing to our currentsuccess with Tesco. These will be rolled outNationwide from Buckie in the North ofScotland and as far south as Devon andCornwall”.

Britspace continue to collaborate withTesco with the objective of developing a fullmodular retail store using the latestmethods of offsite construction.

New member

Fusion Building Systems was establishedin 2000, in response to a growing demandfor offsite building solutions in the UK andIreland. Having invested in the relocation ofthe two former manufacturing sites into one80,000 sqft, “fitted out for purpose”,centrally located Northamptonmanufacturing base, Fusion continues tolead the way in offsite methods ofconstruction with the design, manufactureand installation of light gauge steel framestructures.

Fusion’s key products are:

� pre-insulated, light gauge steel framebuildings

� infill panels using Fusion patentedStIF™ panel technology

� light gauge steel flooring cassettes.

The company, one of the UK’s largestproducers of pre-insulated light gauge steelstructural building systems continues todevelop its legacy of significantly reducingon-site build times enabling fastercompletion, improving health and safetyand reductions in environmental impact.

Fusion’s complete service offering takes acustomer from design, throughmanufacture, and on to installation on site.The superior technical performance of theFusion products is fully certified and tested.

Fusion has significant experience in havingsupplied and installed building systems toover 5,000 buildings, ranging from carehomes and housing developments of up to700 homes to luxury six storey apartmentdevelopments to various hotels and even afive star hotel complex, not forgettingnumerous individual dwellings.

Our average contract value is around£550,000 ranging from £35,000 to projectsin excess of £2m, which clearly shows theflexibility of the product and themanufacturing process.

The key to success is the involvement ofthe Fusion “design team” at the veryearliest stages of a potential project. Thisenables us to work with our client andassess the realistic potential for the systemas a solution. Furthermore the vastexperience of the team simplifies the wholedesign/pre-con stage working closely withthe client and the clients architectsreducing design times and costs.

Our structural engineers are on hand atevery stage of the process from designright through to completion often initiallyadvising on the basic structure and then online loads optimising slab build up andcosts accordingly. Each project is then

516

For more information contact:

Emma Cade on tel: 01430 444504 or

Monika Kubacka on tel: 01430 444551

For more information on Caledonian visit:

www.cbuildings.co.uk

www.buildoffsite.com www.buildoffsite.com

designed, framed and erected with thestructural engineer “signing off” the jobupon completion.

This approach along with the patented preinsulated panel technology are cleardifferentiators and as more and more newclients take their first steps towards a “builtoff site” solution the reassurance andadvice the team deliver is an essentialingredient in our success.

In addition to our structural external panelswe are experiencing increasing demandsfor our “in-fill panels” for concrete orstructural steel buildings. These panels aredesign engineered to enclose the buildingallowing follow on trades to commencetheir work sooner. With robust deflectionplates and high quality fixings our systemdelivers an excellent solution. Our ability tofit these panels from within the building candramatically reduce costs of scaffolding andagain decrease build times.

Delivering essential change

A high level discussion hosted byBuildoffsiteBuildoffsite is convinced that the currentcommercial pressures within the UKeconomy will encourage more and moreclients to react against the status quo interms of how projects are delivered. Webelieve that clients will increasinglyrecognise that their requirements in termsof increased value, cost and time certainty,

quality and enhanced sustainability willstimulate the opportunities for offsitesolutions to take an increasing share of theUK construction market.

To encourage informed discussion aboutthe need for change within the industryBuildoffsite hosted an invitation only eventfor senior clients and constructors.Notwithstanding travel disruption caused bysnow and freezing temperatures the event,which took place on 1 December, wasattended by almost 30 senior figures. Themeeting was facilitated by Tim Hall andChris Ellins of TotalFlow – a BuildoffsiteMember Organisation

The context for the discussion was set outunder five headings comprising:

� incentivising investment in construction

� delivering better performing, moresustainable buildings

� achieving step-change increases inproductivity

� offering substantial improvements inclient value

� enabling the supply side to earn areasonable profit.

The discussion that followed recognisedthe need for change and started to identifythe specific actions that clients and thesupply chain could take to introducefundamental improvements in theperformance of the industry. The discussionwas informed by worked examples from anumber of the leading clients present,which included sustained programmes ofcontinuous improvement in the integrationof design and construction and the

aware that a number of featuredconstruction projects have benefited fromthe application of lean project managementservices provided by Lean Thinking Ltd toincrease client value, project performance,profitability and sustainability. In turn theapplication of lean project management hasstimulated the increased take up of offsiteconstruction solutions to ensure certainty ofproject programme, project cost and projectquality. The clients involved have includedthe Ministry of Justice and Marks andSpencer. Main contractors have includedInterserve and ISG.

Construction Skills, Lean Thinking Ltd andBuildoffsite are keen to demonstrate thatthe benefits of lean project managementtechniques are equally applicable to smallprojects as well as large projects, new buildas well as refurbishment, projects alreadyunderway as well as those about to startand are also applicable to the activities ofmanufacturers, suppliers, sub contractorsand designers.

Construction Skills and Lean Thinking Ltdhave come up with a scheme that, in thefirst instance, is being made available tothose Buildoffsite members who wish toimplement lean project managementtechniques to the delivery of their projectsand services. Put simply the offer is that ifas a result of the facilitated application oflean project management the project andthe applicant have not benefited fromtangible improvements the professionalfees incurred will be refunded. There will ofcourse be an obligation that the seniormanagement of the applicant organisationsgive their total support to theimplementation process.

The outputs from this trial programme willbe independently verified and case studieswill be produced by Construction Skills tofurther demonstrate the project andorganisational value of lean projectmanagement techniques along with theassociated requirements for new skills. Theoutputs will be promoted at futureBuildoffsite events.

Caledonian case study – Surrey

St, Croydon

The Bridge House development in Croydonoccupies an L-shaped site inbetween themain market street in Croydon and an NCPcar park. Due to the tight nature of the sitea 500 tonnes crane was used to lift themodules into place. Once in place a bridgewas constructed from the new apartmentdevelopment to link into the neighbouringshopping centre to provide easy access forresidents.

As the development was within the M25and module widths were around 4m, nighttime deliveries and installation wasrequired.

The modules sit on a concrete plinth, withretail units on the ground floor. One of theunusual aspects of this project was thatstair and lift shaft modules were extendedthrough the concrete plinth to level -1,which meant that with an in situ staircase,instant access was provided to the modularstructure above.

6 15

If you think that your company might be

interested in getting involved and have a

project or a construction activity in mind

that you think might benefit from the

application of lean project management

services contact Ali Mafi, Lean Thinking

Ltd (see below for contact details).

If you would like copies of existing project

case studies that provide information on

the practical outcome from the application

of lean project management contact Ali

Mafi on:

Email: mafia@lean-thinking.co.uk

Tel: 07974 138 283

www.buildoffsite.com www.buildoffsite.com

“The announcement is tangible evidence ofthe role Laing O’Rourke is committed toplaying in this regard, and we are excitedby the prospect of sharing our vision andforging an enduring relationship withCambridge University, in line with our othereducational partnerships.”

Professor Dame Ann Dowling, Head of theDepartment of Engineering said: “Thedepartment’s aim is to address the world’smost pressing challenges through ourteaching and research. I am excited by thepotential of this new centre to developnovel solutions to the challenges ofconstructing a built environment that issustainable whilst providing for the needsof society to supply energy, water, shelter,and a transport infrastructure on whicheconomic well-being depends. I am gratefulto Laing O’Rourke for their commitmentand to Ray O’Rourke for his vision.”

QUBE Group buys out PCSL

Partner Tarmac

Qube Group has acquired from Tarmac Ltd,its 50 per cent share of Precast CellularStructures Ltd (PCSL), the specialist prisonhouseblock builder.

Following the transaction, Qube Group, theparent company of design and buildcontractor Composite Ltd, now controls 100per cent of PCSL. The group has owned 50per cent of the company since 1996, whenComposite set up PCSL as a joint venturewith Tarmac, to be part of the first PFIprison project in the country.

Since then, PCSL has completed morethan thirty projects in the custodial sector,providing in excess of 5,200 cells. In thepast 12 months, the company hascompleted houseblock projects at HMPNottingham, Swaleside and Long Lartin, allof which have achieved BREEAM Excellentstatus.

Qube Group Managing Director, Roy Nield-Dumper said: “This purchase will enable usto consolidate and focus our activities onfurther developing our modular approach todelivering outstanding prisonaccommodation.”

Modular construction is perfectly suited tothe specific requirements of the custodialsector due to its competitive cost, safetyand security, high quality, low maintenancecosts and speed of construction.

Composite designed and constructed itsfirst houseblock for PCSL in 1995 at HMPFazakerley (later renamed Altcourse), nearLiverpool, Britain’s first PFI prison. In total ithas built 32 precast concrete, modularprison houseblocks in the British Isles,including six for the Scottish PrisonService, and one in Guernsey.

Lean project management:

getting involved

A collaboration between ConstructionSkills, Buildoffsite and Lean Thinking Ltd isbehind the unique offer to facilitate theimplementation of a lean projectmanagement.

On offer is an invitation to all sectors of theconstruction industry to take up facilitatedimplementation of lean projectmanagement system on their projects witha money back guarantee.

This system applies to every stage of theproject including pre-construction anddesign.

Those who have attended recentBuildoffsite Stakeholder events will be

adoption of modern methods of deliverythat were already showing cost reductionsof around 30 per cent. Switching fromconstruction using traditional on-sitemethods in favour of the on-site assemblyof off-site manufactured elementsrepresents a key contributory factor toachieving this level of success.

Those attending the meeting wereunanimously in favour of reconvening tocontinue the discussion and to identifypractical opportunities to collaborate ontaking matters forward. Buildoffsite andTotalflow will be arranging a follow upmeeting along with a separate catch upmeeting for those who wanted to be at the1 December event but were prevented fromattending because of the bad weather.

Buildoffsite news

The Buildoffsite Registration Scheme,operated by Lloyd’s Register EMEA isgathering momentum in the UKconstruction sector.

Working in conjunction with Building LifePlans (Allianz) and with the direction andsupport of the Royal Institute of CharteredSurveyors (RICS) and Buildoffsite, Lloyd’sRegister has now developed the PropertyAssurance Scheme. The scheme has beendeveloped to provide assurance to

mortgage lenders that they will not beexposed to undue risk in lending againstproperties constructed using innovativeconstruction methods.

Following a successful presentation to thelenders at the RICS in July, four of theprincipal lenders, Lloyd’s TSB, Santander,Nationwide and RBS have agreed toparticipate in a number of pilotdevelopment projects that will be operatedunder the assurance scheme.

The assurance scheme comprises:

� accreditation against good practice indesign, manufacture and construction

� 60 year durability assessment of thesystem of construction

� 12 year latent defect insurance

� web accessed database, which detailsthe structural elements of each propertyby postcode.

This represents a major breakthrough forthe non-traditional construction sector,critical to achieving the UK Government’s2020 carbon emissions target, as to datethe lenders have been loathe to risk lendingagainst innovatively designed andconstructed properties.

New accreditations

Lloyd’s Register has recently accreditedUnite Modular Solutions Ltd (UMS) underthe Buildoffsite Registration Scheme in thedesign, manufacturing and constructionscopes. Unite Modular Solutions Ltd, basedin Gloucestershire, has designed,manufactured and installed some 17,000fully fitted volumetric modules into a diverserange of projects across the UK since itsinception in 2002. At the award ceremony,Richard Ogden, Chairman of Buildoffsitesaid: “Buildoffsite are delighted to presentthis certificate to Unite, which is atestament to the application of best practicein the delivery of design, manufacture andconstruction to the offsite constructionindustry.”

714

Richard Ogden, Chairman of Buildoffsite,presenting the certificate to Ron Brown, QualityAssurance and Safety Manager at Unite

Buildoffsite will shortly be publishing a

précis of the discussion points from the 1

December event including a commentary

on the potential next steps. The details will

be reported on the Buildoffsite website:

www.buildoffsite.com

www.buildoffsite.com www.buildoffsite.com

Become a signatory

Laing O’Rourke

and Cambridge

University to establish Centre

of Excellence in Engineering

Laing O’Rourke and The University ofCambridge have today announced thecreation of a new multi-disciplinaryacademic centre of excellence to advancethe engineering profession and leverageinnovative thinking to benefit theconstruction industry.

The UK’s largest privately-ownedengineering enterprise, Laing O’Rourke,will fund the Laing O’Rourke Centre forConstruction Engineering and Technologyat Cambridge as part of their multi-millionpound collaboration with the University.

An agreement signed by Cambridge Vice-Chancellor Professor Dame Alison Richard,and Laing O’Rourke Chairman and ChiefExecutive Ray O’Rourke formally launchedthe new centre, which is set to play aleading role in shaping the future of theconstruction industry by responding to theenvironmental and sustainability challengesfacing the planet.

The Centre will be a focus for innovativeresearch and teaching, using the insights tohelp shape the built environment of thefuture in order to give as many people aspossible access to the benefits ofsustainable construction.

A new two year part-time Masters degree inConstruction Engineering will be launchedin September 2011 by the Centre in theUniversity’s Department of Engineering,working with Judge Business School.

This course aims to advance thedevelopment of the construction sectorthrough the translation of intellectualachievement into practical outcomes. It willproduce engineers and managers who willlead the process of breaking down thetraditional barriers between construction,consulting engineering and the client,pushing forward an agenda of innovationand technological advancement.

It will encompass the full spectrum of theindustry value chain from the high-levelfinancing requirements of major projectsthrough to the latest innovations inanalysis, design and materials technology,with a focus on sustainability and whole-lifeperformance. The programme will bemultidisciplinary aiming to embrace a broadrange of sectors such as housing,buildings, transport, energy, water andwaste.

The Centre, led by the new Laing O’RourkeProfessor of Construction Engineering, willalso deliver undergraduate education, PhDand post-doctoral research and ExecutiveEducation. A key goal is to raise the profileof the construction industry across the UK,attracting more young people to considercareers in this field and fast-tracking themthrough to senior management positions.

Ray O’Rourke said: “I believe theengineering and construction professionhas reached a critical crossroads in itsdevelopment – it has for too long relied ontraditional skills and approaches, oftenfailing to keep pace with the political, socialand economic demands of modern society.It must once again attract the very besttalent, apply radical thinking, embrace newtechnologies and innovate in a way thatremoves waste and inefficiency and createsthe greatest value for the world’scommunities.

You are invited to put your organisation’s

name as a signatory to the proposition. It

involves a commitment to display

voluntarily a DEC in all your office

buildings over 1,000 m² by December 2011.

To commit your support to this, please

email now with your company logo for the

signatory list below. This proposition, with

the list of signatories, will also be taken to

Government through a variety of means.

Email: val.grundy@ngbailey.co.uk

NG Bailey appoint business

development manager

Leading national building services providerNG Bailey has announced the appointmentof a new business development managerfor its off-site manufacturing division.

The Ilkley-based company, with itsheadquarters at Denton Hall, has appointedJason Malik business developmentmanager of the West Yorkshire-baseddivision.

He will be responsible for developing thedivision’s external customer base with anemphasis on formulating and implementinga strategic approach to new markets.

He has previously worked in businessdevelopment roles at companies includingHewden PLC GE Capital Modular Spaceand Elliot Modular Buildings as nationalaccounts director.

Mr Malik said: “I am delighted to havejoined NG Bailey. I have long since admiredthe company’s dedication to high standardsand I look forward to being a part of such awell-respected company, one with areputation for delivering innovation in theoff-site manufacturing field.

As a founder member of Buildoffsite, NGBailey continues to lead in this field,bringing solutions to the table that will yieldlower costs, improve H&S due to areduction of labour on site, whilst alsoreducing transportation and waste.”

UNITE modular solutions gains

constructionline accreditation

Unite Modular Solutions Ltd, industryleaders in off-site volumetric construction,has further boosted its standing in theconstruction industry after gaining theConstructionline accreditation.

Constructionline is a nationally recognisedregistration board that supplies over 2000organisations working within the buildingsector with its approved suppliers anddetails of relevant scopes of excellence.

The service is recommended by the OGCCommon Minimum Standards and TheLocal Government Task Force and helpsmake significant administration savings forthe client by linking them with relevantapproved suppliers.

Unite Modular Solutions Ltd (UMS)achieved the accreditation by completingan exhaustive pre-qualificationquestionnaire, which was supplemented bya comprehensive suite of documentedevidence demonstrating compliance in anumber of key areas of off-site volumetricmanufacture and installation.

Ron Brown, SQA manager for UMS,comments: “Gaining this accreditation isanother success for UMS and will help toenhance the company’s already excellentreputation within the industry. HavingConstructionline accreditation will simplifythe tendering process as most majorpotential construction customers and localgovernment accept it, thus alleviating theneed for protracted pre qualificationquestionnaires.”

8 13

Jason Malik

For more information please visit:

www.unite-modular-solutions.co.uk

www.buildoffsite.com www.buildoffsite.com

Project SLAM

The 15,000th Project SLAM bedroom hasbeen completed thanks to modulesprovided by Caledonian Building Systems.The £500m project is modernising thesingle living accommodation for the armedforces throughout the UK.

This project is being delivered by DebutServices Limited for the Ministry of Defence(MoD). Graham Jeffery, Project SLAMProgram Director at Debut Services Ltdcomments: “We are delighted to havereached the 15,000 bedroom milestonewith the help of Caledonian, workingclosely with them has helped us to deliverquality accommodation for servicepersonnel on a large scale across thecountry, in a highly efficient and sustainableway. Modular construction will continue toplay a principal role in delivery of thisproject.”

Yorkon wins another award for

NHS treatment centre

Off-site constructionspecialist and Portakabinsubsidiary, Yorkon, haswon another award forthe acclaimed EmersonsGreen NHS TreatmentCentre in Bristol.

The project for independent healthcareproviders UK Specialist Hospitals (UKSH)is believed to be the largest completehospital to be built using modularconstruction.

The scheme has just won the award forBest Product Used in the ExteriorEnvironment at the Building BetterHealthcare Awards.

The awards are the UK’s most prestigiousfor healthcare design and facilitiesmanagement, celebrating the people,products and projects that have excelled inimproving the healthcare environment.

According to the judges: “Each year thestandard of entries has grown…..a positiveindication of the ever-improvingenvironment of the country’s health service.The winners of this year’s awards have farexceeded present standards in today’shealthcare built community. As pioneers ofthe future environment of our healthcare,these winners have set a benchmark for allfuture developments, and as a result,should be congratulated.”

Designed by architects TP Bennett andbuilt by Yorkon, the Emersons Green NHSTreatment Centre is a new purpose-builtsurgical hospital, which provides a range ofelective surgical services for NHS patients,including inpatient treatment.

Commenting on the latest award for theproject, David Johnson, Director andGeneral Manager of Yorkon said: “Tocomplete a project of this scale andcomplexity, which was open and treating

Government may be willing to support suchlegislation, and will find this easier if thereis a groundswell of support from majorbusinesses and industry bodies.

The proposition has been developed andchampioned by Cal Bailey, NG Bailey’ssustainability director, with the activesupport of BSRIA, Buildoffsite and theUKGBC. It is also gaining backing fromother businesses that see the value ofdemonstrating continuing improvement oftheir property assets. We are thereforeseeking to co-ordinate a list of leadingproperty and construction businesses thatsupport efforts to reduce CO2 emissionsfrom buildings and are willing to take aleadership stance by signingthe proposition below.

The proposition: marketincentivisation by visible DECs innon-domestic buildingsCarbon is invisible, out of sight and largelyout of mind. Buildings represent the singlelargest cause of carbon release but this ispoorly understood, and it is hard todifferentiate between good and badperformers. This problem was overcome inthe white goods market by making energyperformance visible via the familiar energylabel, which has successfully driven thedevelopment of greener products.

The property market needs strongerincentives to enable landlords both to buildbetter new buildings and especially torefurbish existing buildings to higher energystandards.

If non-domestic buildings displayed theirDEC performance prominently in circulationareas (especially receptions), this would:

� raise the awareness of users to theirbuilding’s energy performance

� drive tenants to require higherperformance from future premises

� raise the value of better performingbuildings

� properly reward landlords who construct/refurbish buildings to high energystandards.

We recognise that government is reluctantto regulate. However, we believe theprominent display of DECs will drive theright behaviour and incentives, and so callon the government to require this.

We are willing to demonstrate our supportfor this proposal and our leadership in thismatter by committing to place prominentDECs in our non-domestic office buildingsover 1,000 m² by December 2011.

Signatories to date:

912

For more information contact:

Suzanne Bennett email:

sbennett@camarguepr.com

Isobel Shayle email:

ishayle@camarguepr.com

or tel: 01242 577 277

www.buildoffsite.com www.buildoffsite.com

Foremans releases new figures

for delivery on time, on budget

and customer satisfaction

research results

Figures just released by ForemansRelocatable Building Systems, the UK’slargest supplier of recycled and refurbishedmodular buildings, have shown how itsapproach is delivering outstandingcustomer satisfaction and the consistentcompletion of projects on time and onbudget.

Foremans has successfully delivered 96per cent of its projects on time and 99 percent on budget in the last three years.

This performance is in sharp contrast togovernment statistics for the UK buildingindustry, which showed that only 46 percent of construction projects werecompleted on cost and only 59 per cent ontime last year (source: ConstructionStatistics Annual, Office of Public SectorInformation, 2009).

In research carried out to measurecustomer service, Foremans achieved anaverage score of 91 per cent for overallsatisfaction, including both building andservice quality, over the last two years. 100per cent of customers surveyed wouldrecommend Foremans building solutions.

A further endorsement of the Foremansapproach is the fact that 80 per cent of itsbusiness is from past customers.

Commenting on the new figures andresearch results, Kevin Jones, ManagingDirector of Foremans Relocatable BuildingSystems, said: “We believe these resultsreinforce our position as the UK’s leadingsupplier of recycled and refurbishedmodular buildings. Our teams both on andoff site work tremendously hard to ensure

we deliver the highest levels of customerservice on every project, and ouroutstanding performance over the pastthree years, is testament to their ongoingcommitment, as well as the quality of ourbuildings.”

Our approach to re-using quality modularbuildings combines all the advantages ofoff-site construction – speed and reduceddisruption – with the additional benefits ofexceptional cost efficiency, shorter leadtimes and greater sustainability.

Foremans building solutions meet therequirements of the revised BuildingRegulations Part L2A 2010 (England andWales) and Section 6 2010 (Scotland).Each building is fully refurbished off site atone of Foremans’ two production centres.Only the structure of the building isrecycled, adding even more value to thepre-owned modular approach.

The buildings are reconfigured to exactproject requirements and specification, andfitted with new windows, wall linings,partitions, M&E services, doors andflooring, creating high qualityaccommodation for a range of permanentand interim uses.

Building energy reduction

There is now widespread agreementthat DECs (Display Energy Certificates) –prominently displayed in every building –will, over time, create the necessaryawareness amongst occupiers. This willdrive a desire for buildings with betterenergy performance among tenants. ItThiswill create differential rents incentivisinglandlords appropriately to undertake energyfocused refurbishment.

patients just 12 months after the start onsite, was a significant achievement for thewhole project team.

It involved taking an innovative approach toconstruction that minimised on-site workingand reduced the programme time – and itwas successfully delivered both on timeand on budget.”

We are absolutely delighted with this latestaward, and the recognition it gives to theclient, the design and construction team,and to the success of the off-siteapproach.”

The three-storey 4,842 sqm hospitalcomprises 114 steel modules that Yorkoncraned into position in just three weeks toreduce the build time to only 12 months.The programme was critical as patientswere booked in for treatment, and wasachieved despite winter working andadverse weather conditions, which wouldhave had a major impact on traditional site-based construction methods.

The project’s other achievements included:

� challenging programme. Within just fourweeks of Yorkon’s contract award, theinfrastructure works had been completedready to receive the speciallymanufactured modules

� outstanding site management. Yorkon’ssite management team was recognisedwith Considerate Constructors“Performance Beyond Compliance”certification

� excellence in health and safety. Therewere no reportable incidents oraccidents on the site for the duration ofthe project and in more than 120,000man hours.

� an attractive, welcoming healthcarefacility. The building demonstrates thedesign flexibility and architectural qualityof off-site construction

� innovative floor solution. The schemewas the first application in the healthcaresector of the new Yorkon highperformance pre-installed concrete floorsystem

� integrating off-site construction and site-based building methods. A highly glazedtraditionally-constructed atrium to thefront elevation demonstrates howmodular construction can besuccessfully integrated with conventionalbuilding methods.

The treatment centre also has strongenvironmental credentials. It achieved aBREEAM “very good” rating and featuresservices monitoring, water conservationdevices, a high level of natural light, solarreflective glass, leak detection system forthe kitchen, and cycle storage. Asustainable green roof was used for theadjacent service building.

The project has already won an LABCBuilding Excellence Award, and wasYorkon’s third healthcare project for UKSH.

10 11

For further information about recycled and

refurbished modular buildings

Website: www.foremansbuildings.info

Email: info@foremansbuildings.co.uk

Tel: 01964 544344

www.buildoffsite.com www.buildoffsite.com

Foremans releases new figures

for delivery on time, on budget

and customer satisfaction

research results

Figures just released by ForemansRelocatable Building Systems, the UK’slargest supplier of recycled and refurbishedmodular buildings, have shown how itsapproach is delivering outstandingcustomer satisfaction and the consistentcompletion of projects on time and onbudget.

Foremans has successfully delivered 96per cent of its projects on time and 99 percent on budget in the last three years.

This performance is in sharp contrast togovernment statistics for the UK buildingindustry, which showed that only 46 percent of construction projects werecompleted on cost and only 59 per cent ontime last year (source: ConstructionStatistics Annual, Office of Public SectorInformation, 2009).

In research carried out to measurecustomer service, Foremans achieved anaverage score of 91 per cent for overallsatisfaction, including both building andservice quality, over the last two years. 100per cent of customers surveyed wouldrecommend Foremans building solutions.

A further endorsement of the Foremansapproach is the fact that 80 per cent of itsbusiness is from past customers.

Commenting on the new figures andresearch results, Kevin Jones, ManagingDirector of Foremans Relocatable BuildingSystems, said: “We believe these resultsreinforce our position as the UK’s leadingsupplier of recycled and refurbishedmodular buildings. Our teams both on andoff site work tremendously hard to ensure

we deliver the highest levels of customerservice on every project, and ouroutstanding performance over the pastthree years, is testament to their ongoingcommitment, as well as the quality of ourbuildings.”

Our approach to re-using quality modularbuildings combines all the advantages ofoff-site construction – speed and reduceddisruption – with the additional benefits ofexceptional cost efficiency, shorter leadtimes and greater sustainability.

Foremans building solutions meet therequirements of the revised BuildingRegulations Part L2A 2010 (England andWales) and Section 6 2010 (Scotland).Each building is fully refurbished off site atone of Foremans’ two production centres.Only the structure of the building isrecycled, adding even more value to thepre-owned modular approach.

The buildings are reconfigured to exactproject requirements and specification, andfitted with new windows, wall linings,partitions, M&E services, doors andflooring, creating high qualityaccommodation for a range of permanentand interim uses.

Building energy reduction

There is now widespread agreementthat DECs (Display Energy Certificates) –prominently displayed in every building –will, over time, create the necessaryawareness amongst occupiers. This willdrive a desire for buildings with betterenergy performance among tenants. ItThiswill create differential rents incentivisinglandlords appropriately to undertake energyfocused refurbishment.

patients just 12 months after the start onsite, was a significant achievement for thewhole project team.

It involved taking an innovative approach toconstruction that minimised on-site workingand reduced the programme time – and itwas successfully delivered both on timeand on budget.”

We are absolutely delighted with this latestaward, and the recognition it gives to theclient, the design and construction team,and to the success of the off-siteapproach.”

The three-storey 4,842 sqm hospitalcomprises 114 steel modules that Yorkoncraned into position in just three weeks toreduce the build time to only 12 months.The programme was critical as patientswere booked in for treatment, and wasachieved despite winter working andadverse weather conditions, which wouldhave had a major impact on traditional site-based construction methods.

The project’s other achievements included:

� challenging programme. Within just fourweeks of Yorkon’s contract award, theinfrastructure works had been completedready to receive the speciallymanufactured modules

� outstanding site management. Yorkon’ssite management team was recognisedwith Considerate Constructors“Performance Beyond Compliance”certification

� excellence in health and safety. Therewere no reportable incidents oraccidents on the site for the duration ofthe project and in more than 120,000man hours.

� an attractive, welcoming healthcarefacility. The building demonstrates thedesign flexibility and architectural qualityof off-site construction

� innovative floor solution. The schemewas the first application in the healthcaresector of the new Yorkon highperformance pre-installed concrete floorsystem

� integrating off-site construction and site-based building methods. A highly glazedtraditionally-constructed atrium to thefront elevation demonstrates howmodular construction can besuccessfully integrated with conventionalbuilding methods.

The treatment centre also has strongenvironmental credentials. It achieved aBREEAM “very good” rating and featuresservices monitoring, water conservationdevices, a high level of natural light, solarreflective glass, leak detection system forthe kitchen, and cycle storage. Asustainable green roof was used for theadjacent service building.

The project has already won an LABCBuilding Excellence Award, and wasYorkon’s third healthcare project for UKSH.

10 11

For further information about recycled and

refurbished modular buildings

Website: www.foremansbuildings.info

Email: info@foremansbuildings.co.uk

Tel: 01964 544344

www.buildoffsite.com www.buildoffsite.com

Project SLAM

The 15,000th Project SLAM bedroom hasbeen completed thanks to modulesprovided by Caledonian Building Systems.The £500m project is modernising thesingle living accommodation for the armedforces throughout the UK.

This project is being delivered by DebutServices Limited for the Ministry of Defence(MoD). Graham Jeffery, Project SLAMProgram Director at Debut Services Ltdcomments: “We are delighted to havereached the 15,000 bedroom milestonewith the help of Caledonian, workingclosely with them has helped us to deliverquality accommodation for servicepersonnel on a large scale across thecountry, in a highly efficient and sustainableway. Modular construction will continue toplay a principal role in delivery of thisproject.”

Yorkon wins another award for

NHS treatment centre

Off-site constructionspecialist and Portakabinsubsidiary, Yorkon, haswon another award forthe acclaimed EmersonsGreen NHS TreatmentCentre in Bristol.

The project for independent healthcareproviders UK Specialist Hospitals (UKSH)is believed to be the largest completehospital to be built using modularconstruction.

The scheme has just won the award forBest Product Used in the ExteriorEnvironment at the Building BetterHealthcare Awards.

The awards are the UK’s most prestigiousfor healthcare design and facilitiesmanagement, celebrating the people,products and projects that have excelled inimproving the healthcare environment.

According to the judges: “Each year thestandard of entries has grown…..a positiveindication of the ever-improvingenvironment of the country’s health service.The winners of this year’s awards have farexceeded present standards in today’shealthcare built community. As pioneers ofthe future environment of our healthcare,these winners have set a benchmark for allfuture developments, and as a result,should be congratulated.”

Designed by architects TP Bennett andbuilt by Yorkon, the Emersons Green NHSTreatment Centre is a new purpose-builtsurgical hospital, which provides a range ofelective surgical services for NHS patients,including inpatient treatment.

Commenting on the latest award for theproject, David Johnson, Director andGeneral Manager of Yorkon said: “Tocomplete a project of this scale andcomplexity, which was open and treating

Government may be willing to support suchlegislation, and will find this easier if thereis a groundswell of support from majorbusinesses and industry bodies.

The proposition has been developed andchampioned by Cal Bailey, NG Bailey’ssustainability director, with the activesupport of BSRIA, Buildoffsite and theUKGBC. It is also gaining backing fromother businesses that see the value ofdemonstrating continuing improvement oftheir property assets. We are thereforeseeking to co-ordinate a list of leadingproperty and construction businesses thatsupport efforts to reduce CO2 emissionsfrom buildings and are willing to take aleadership stance by signingthe proposition below.

The proposition: marketincentivisation by visible DECs innon-domestic buildingsCarbon is invisible, out of sight and largelyout of mind. Buildings represent the singlelargest cause of carbon release but this ispoorly understood, and it is hard todifferentiate between good and badperformers. This problem was overcome inthe white goods market by making energyperformance visible via the familiar energylabel, which has successfully driven thedevelopment of greener products.

The property market needs strongerincentives to enable landlords both to buildbetter new buildings and especially torefurbish existing buildings to higher energystandards.

If non-domestic buildings displayed theirDEC performance prominently in circulationareas (especially receptions), this would:

� raise the awareness of users to theirbuilding’s energy performance

� drive tenants to require higherperformance from future premises

� raise the value of better performingbuildings

� properly reward landlords who construct/refurbish buildings to high energystandards.

We recognise that government is reluctantto regulate. However, we believe theprominent display of DECs will drive theright behaviour and incentives, and so callon the government to require this.

We are willing to demonstrate our supportfor this proposal and our leadership in thismatter by committing to place prominentDECs in our non-domestic office buildingsover 1,000 m² by December 2011.

Signatories to date:

912

For more information contact:

Suzanne Bennett email:

sbennett@camarguepr.com

Isobel Shayle email:

ishayle@camarguepr.com

or tel: 01242 577 277

www.buildoffsite.com www.buildoffsite.com

Become a signatory

Laing O’Rourke

and Cambridge

University to establish Centre

of Excellence in Engineering

Laing O’Rourke and The University ofCambridge have today announced thecreation of a new multi-disciplinaryacademic centre of excellence to advancethe engineering profession and leverageinnovative thinking to benefit theconstruction industry.

The UK’s largest privately-ownedengineering enterprise, Laing O’Rourke,will fund the Laing O’Rourke Centre forConstruction Engineering and Technologyat Cambridge as part of their multi-millionpound collaboration with the University.

An agreement signed by Cambridge Vice-Chancellor Professor Dame Alison Richard,and Laing O’Rourke Chairman and ChiefExecutive Ray O’Rourke formally launchedthe new centre, which is set to play aleading role in shaping the future of theconstruction industry by responding to theenvironmental and sustainability challengesfacing the planet.

The Centre will be a focus for innovativeresearch and teaching, using the insights tohelp shape the built environment of thefuture in order to give as many people aspossible access to the benefits ofsustainable construction.

A new two year part-time Masters degree inConstruction Engineering will be launchedin September 2011 by the Centre in theUniversity’s Department of Engineering,working with Judge Business School.

This course aims to advance thedevelopment of the construction sectorthrough the translation of intellectualachievement into practical outcomes. It willproduce engineers and managers who willlead the process of breaking down thetraditional barriers between construction,consulting engineering and the client,pushing forward an agenda of innovationand technological advancement.

It will encompass the full spectrum of theindustry value chain from the high-levelfinancing requirements of major projectsthrough to the latest innovations inanalysis, design and materials technology,with a focus on sustainability and whole-lifeperformance. The programme will bemultidisciplinary aiming to embrace a broadrange of sectors such as housing,buildings, transport, energy, water andwaste.

The Centre, led by the new Laing O’RourkeProfessor of Construction Engineering, willalso deliver undergraduate education, PhDand post-doctoral research and ExecutiveEducation. A key goal is to raise the profileof the construction industry across the UK,attracting more young people to considercareers in this field and fast-tracking themthrough to senior management positions.

Ray O’Rourke said: “I believe theengineering and construction professionhas reached a critical crossroads in itsdevelopment – it has for too long relied ontraditional skills and approaches, oftenfailing to keep pace with the political, socialand economic demands of modern society.It must once again attract the very besttalent, apply radical thinking, embrace newtechnologies and innovate in a way thatremoves waste and inefficiency and createsthe greatest value for the world’scommunities.

You are invited to put your organisation’s

name as a signatory to the proposition. It

involves a commitment to display

voluntarily a DEC in all your office

buildings over 1,000 m² by December 2011.

To commit your support to this, please

email now with your company logo for the

signatory list below. This proposition, with

the list of signatories, will also be taken to

Government through a variety of means.

Email: val.grundy@ngbailey.co.uk

NG Bailey appoint business

development manager

Leading national building services providerNG Bailey has announced the appointmentof a new business development managerfor its off-site manufacturing division.

The Ilkley-based company, with itsheadquarters at Denton Hall, has appointedJason Malik business developmentmanager of the West Yorkshire-baseddivision.

He will be responsible for developing thedivision’s external customer base with anemphasis on formulating and implementinga strategic approach to new markets.

He has previously worked in businessdevelopment roles at companies includingHewden PLC GE Capital Modular Spaceand Elliot Modular Buildings as nationalaccounts director.

Mr Malik said: “I am delighted to havejoined NG Bailey. I have long since admiredthe company’s dedication to high standardsand I look forward to being a part of such awell-respected company, one with areputation for delivering innovation in theoff-site manufacturing field.

As a founder member of Buildoffsite, NGBailey continues to lead in this field,bringing solutions to the table that will yieldlower costs, improve H&S due to areduction of labour on site, whilst alsoreducing transportation and waste.”

UNITE modular solutions gains

constructionline accreditation

Unite Modular Solutions Ltd, industryleaders in off-site volumetric construction,has further boosted its standing in theconstruction industry after gaining theConstructionline accreditation.

Constructionline is a nationally recognisedregistration board that supplies over 2000organisations working within the buildingsector with its approved suppliers anddetails of relevant scopes of excellence.

The service is recommended by the OGCCommon Minimum Standards and TheLocal Government Task Force and helpsmake significant administration savings forthe client by linking them with relevantapproved suppliers.

Unite Modular Solutions Ltd (UMS)achieved the accreditation by completingan exhaustive pre-qualificationquestionnaire, which was supplemented bya comprehensive suite of documentedevidence demonstrating compliance in anumber of key areas of off-site volumetricmanufacture and installation.

Ron Brown, SQA manager for UMS,comments: “Gaining this accreditation isanother success for UMS and will help toenhance the company’s already excellentreputation within the industry. HavingConstructionline accreditation will simplifythe tendering process as most majorpotential construction customers and localgovernment accept it, thus alleviating theneed for protracted pre qualificationquestionnaires.”

8 13

Jason Malik

For more information please visit:

www.unite-modular-solutions.co.uk

www.buildoffsite.com www.buildoffsite.com

“The announcement is tangible evidence ofthe role Laing O’Rourke is committed toplaying in this regard, and we are excitedby the prospect of sharing our vision andforging an enduring relationship withCambridge University, in line with our othereducational partnerships.”

Professor Dame Ann Dowling, Head of theDepartment of Engineering said: “Thedepartment’s aim is to address the world’smost pressing challenges through ourteaching and research. I am excited by thepotential of this new centre to developnovel solutions to the challenges ofconstructing a built environment that issustainable whilst providing for the needsof society to supply energy, water, shelter,and a transport infrastructure on whicheconomic well-being depends. I am gratefulto Laing O’Rourke for their commitmentand to Ray O’Rourke for his vision.”

QUBE Group buys out PCSL

Partner Tarmac

Qube Group has acquired from Tarmac Ltd,its 50 per cent share of Precast CellularStructures Ltd (PCSL), the specialist prisonhouseblock builder.

Following the transaction, Qube Group, theparent company of design and buildcontractor Composite Ltd, now controls 100per cent of PCSL. The group has owned 50per cent of the company since 1996, whenComposite set up PCSL as a joint venturewith Tarmac, to be part of the first PFIprison project in the country.

Since then, PCSL has completed morethan thirty projects in the custodial sector,providing in excess of 5,200 cells. In thepast 12 months, the company hascompleted houseblock projects at HMPNottingham, Swaleside and Long Lartin, allof which have achieved BREEAM Excellentstatus.

Qube Group Managing Director, Roy Nield-Dumper said: “This purchase will enable usto consolidate and focus our activities onfurther developing our modular approach todelivering outstanding prisonaccommodation.”

Modular construction is perfectly suited tothe specific requirements of the custodialsector due to its competitive cost, safetyand security, high quality, low maintenancecosts and speed of construction.

Composite designed and constructed itsfirst houseblock for PCSL in 1995 at HMPFazakerley (later renamed Altcourse), nearLiverpool, Britain’s first PFI prison. In total ithas built 32 precast concrete, modularprison houseblocks in the British Isles,including six for the Scottish PrisonService, and one in Guernsey.

Lean project management:

getting involved

A collaboration between ConstructionSkills, Buildoffsite and Lean Thinking Ltd isbehind the unique offer to facilitate theimplementation of a lean projectmanagement.

On offer is an invitation to all sectors of theconstruction industry to take up facilitatedimplementation of lean projectmanagement system on their projects witha money back guarantee.

This system applies to every stage of theproject including pre-construction anddesign.

Those who have attended recentBuildoffsite Stakeholder events will be

adoption of modern methods of deliverythat were already showing cost reductionsof around 30 per cent. Switching fromconstruction using traditional on-sitemethods in favour of the on-site assemblyof off-site manufactured elementsrepresents a key contributory factor toachieving this level of success.

Those attending the meeting wereunanimously in favour of reconvening tocontinue the discussion and to identifypractical opportunities to collaborate ontaking matters forward. Buildoffsite andTotalflow will be arranging a follow upmeeting along with a separate catch upmeeting for those who wanted to be at the1 December event but were prevented fromattending because of the bad weather.

Buildoffsite news

The Buildoffsite Registration Scheme,operated by Lloyd’s Register EMEA isgathering momentum in the UKconstruction sector.

Working in conjunction with Building LifePlans (Allianz) and with the direction andsupport of the Royal Institute of CharteredSurveyors (RICS) and Buildoffsite, Lloyd’sRegister has now developed the PropertyAssurance Scheme. The scheme has beendeveloped to provide assurance to

mortgage lenders that they will not beexposed to undue risk in lending againstproperties constructed using innovativeconstruction methods.

Following a successful presentation to thelenders at the RICS in July, four of theprincipal lenders, Lloyd’s TSB, Santander,Nationwide and RBS have agreed toparticipate in a number of pilotdevelopment projects that will be operatedunder the assurance scheme.

The assurance scheme comprises:

� accreditation against good practice indesign, manufacture and construction

� 60 year durability assessment of thesystem of construction

� 12 year latent defect insurance

� web accessed database, which detailsthe structural elements of each propertyby postcode.

This represents a major breakthrough forthe non-traditional construction sector,critical to achieving the UK Government’s2020 carbon emissions target, as to datethe lenders have been loathe to risk lendingagainst innovatively designed andconstructed properties.

New accreditations

Lloyd’s Register has recently accreditedUnite Modular Solutions Ltd (UMS) underthe Buildoffsite Registration Scheme in thedesign, manufacturing and constructionscopes. Unite Modular Solutions Ltd, basedin Gloucestershire, has designed,manufactured and installed some 17,000fully fitted volumetric modules into a diverserange of projects across the UK since itsinception in 2002. At the award ceremony,Richard Ogden, Chairman of Buildoffsitesaid: “Buildoffsite are delighted to presentthis certificate to Unite, which is atestament to the application of best practicein the delivery of design, manufacture andconstruction to the offsite constructionindustry.”

714

Richard Ogden, Chairman of Buildoffsite,presenting the certificate to Ron Brown, QualityAssurance and Safety Manager at Unite

Buildoffsite will shortly be publishing a

précis of the discussion points from the 1

December event including a commentary

on the potential next steps. The details will

be reported on the Buildoffsite website:

www.buildoffsite.com

www.buildoffsite.com www.buildoffsite.com

designed, framed and erected with thestructural engineer “signing off” the jobupon completion.

This approach along with the patented preinsulated panel technology are cleardifferentiators and as more and more newclients take their first steps towards a “builtoff site” solution the reassurance andadvice the team deliver is an essentialingredient in our success.

In addition to our structural external panelswe are experiencing increasing demandsfor our “in-fill panels” for concrete orstructural steel buildings. These panels aredesign engineered to enclose the buildingallowing follow on trades to commencetheir work sooner. With robust deflectionplates and high quality fixings our systemdelivers an excellent solution. Our ability tofit these panels from within the building candramatically reduce costs of scaffolding andagain decrease build times.

Delivering essential change

A high level discussion hosted byBuildoffsiteBuildoffsite is convinced that the currentcommercial pressures within the UKeconomy will encourage more and moreclients to react against the status quo interms of how projects are delivered. Webelieve that clients will increasinglyrecognise that their requirements in termsof increased value, cost and time certainty,

quality and enhanced sustainability willstimulate the opportunities for offsitesolutions to take an increasing share of theUK construction market.

To encourage informed discussion aboutthe need for change within the industryBuildoffsite hosted an invitation only eventfor senior clients and constructors.Notwithstanding travel disruption caused bysnow and freezing temperatures the event,which took place on 1 December, wasattended by almost 30 senior figures. Themeeting was facilitated by Tim Hall andChris Ellins of TotalFlow – a BuildoffsiteMember Organisation

The context for the discussion was set outunder five headings comprising:

� incentivising investment in construction

� delivering better performing, moresustainable buildings

� achieving step-change increases inproductivity

� offering substantial improvements inclient value

� enabling the supply side to earn areasonable profit.

The discussion that followed recognisedthe need for change and started to identifythe specific actions that clients and thesupply chain could take to introducefundamental improvements in theperformance of the industry. The discussionwas informed by worked examples from anumber of the leading clients present,which included sustained programmes ofcontinuous improvement in the integrationof design and construction and the

aware that a number of featuredconstruction projects have benefited fromthe application of lean project managementservices provided by Lean Thinking Ltd toincrease client value, project performance,profitability and sustainability. In turn theapplication of lean project management hasstimulated the increased take up of offsiteconstruction solutions to ensure certainty ofproject programme, project cost and projectquality. The clients involved have includedthe Ministry of Justice and Marks andSpencer. Main contractors have includedInterserve and ISG.

Construction Skills, Lean Thinking Ltd andBuildoffsite are keen to demonstrate thatthe benefits of lean project managementtechniques are equally applicable to smallprojects as well as large projects, new buildas well as refurbishment, projects alreadyunderway as well as those about to startand are also applicable to the activities ofmanufacturers, suppliers, sub contractorsand designers.

Construction Skills and Lean Thinking Ltdhave come up with a scheme that, in thefirst instance, is being made available tothose Buildoffsite members who wish toimplement lean project managementtechniques to the delivery of their projectsand services. Put simply the offer is that ifas a result of the facilitated application oflean project management the project andthe applicant have not benefited fromtangible improvements the professionalfees incurred will be refunded. There will ofcourse be an obligation that the seniormanagement of the applicant organisationsgive their total support to theimplementation process.

The outputs from this trial programme willbe independently verified and case studieswill be produced by Construction Skills tofurther demonstrate the project andorganisational value of lean projectmanagement techniques along with theassociated requirements for new skills. Theoutputs will be promoted at futureBuildoffsite events.

Caledonian case study – Surrey

St, Croydon

The Bridge House development in Croydonoccupies an L-shaped site inbetween themain market street in Croydon and an NCPcar park. Due to the tight nature of the sitea 500 tonnes crane was used to lift themodules into place. Once in place a bridgewas constructed from the new apartmentdevelopment to link into the neighbouringshopping centre to provide easy access forresidents.

As the development was within the M25and module widths were around 4m, nighttime deliveries and installation wasrequired.

The modules sit on a concrete plinth, withretail units on the ground floor. One of theunusual aspects of this project was thatstair and lift shaft modules were extendedthrough the concrete plinth to level -1,which meant that with an in situ staircase,instant access was provided to the modularstructure above.

6 15

If you think that your company might be

interested in getting involved and have a

project or a construction activity in mind

that you think might benefit from the

application of lean project management

services contact Ali Mafi, Lean Thinking

Ltd (see below for contact details).

If you would like copies of existing project

case studies that provide information on

the practical outcome from the application

of lean project management contact Ali

Mafi on:

Email: mafia@lean-thinking.co.uk

Tel: 07974 138 283

www.buildoffsite.com www.buildoffsite.com

One bedroom apartments, were selfcontained in one complete module, with anexternal walkway constructed for access.Due to the nature of the site, one elevationwas tapered and as a consequenceindividual modules were designed toprovide the required façade. Our client’saspirations were to achieve EcoHomesVery Good Standard. A range of measureswere employed to achieve this including:

� 33% improvement on U-values aboveBuilding Regulations

� 650 sq m of green roof and 60 m sq ofbrown roof

� low voltage lighting within apartmentsand compact downlighters in publicareas

� FSC timber procured (Caledonian hasfull FSC certification)

� Caledonian modular constructionelements have Green Guide A & Bratings

� home office provision

� low ozone depleting materials, which arestandard within the modular construction

� a range of external measures includingrecycling provision, rainwater harvesting,easy access to shops and the localtransport network.

Teaming up with Tesco

We are delighted to announce that Tescohas chosen to partner with Britspace ontheir new store roll out programme for2010/2011. This contract requiresmanufacturing of a new hybrid productcalled “podular”.

Retail Director Paul Bonaccorsi takes upthe story: “When we looked at Tesco’srequirements for back of house units suchas the managers offices, staff and customerWC’s, staff changing rooms, cash officesetc we developed a new product that wasrobust with a limited floor depth, the resultwas a hybrid of modular building andbathroom pods, contributing to our currentsuccess with Tesco. These will be rolled outNationwide from Buckie in the North ofScotland and as far south as Devon andCornwall”.

Britspace continue to collaborate withTesco with the objective of developing a fullmodular retail store using the latestmethods of offsite construction.

New member

Fusion Building Systems was establishedin 2000, in response to a growing demandfor offsite building solutions in the UK andIreland. Having invested in the relocation ofthe two former manufacturing sites into one80,000 sqft, “fitted out for purpose”,centrally located Northamptonmanufacturing base, Fusion continues tolead the way in offsite methods ofconstruction with the design, manufactureand installation of light gauge steel framestructures.

Fusion’s key products are:

� pre-insulated, light gauge steel framebuildings

� infill panels using Fusion patentedStIF™ panel technology

� light gauge steel flooring cassettes.

The company, one of the UK’s largestproducers of pre-insulated light gauge steelstructural building systems continues todevelop its legacy of significantly reducingon-site build times enabling fastercompletion, improving health and safetyand reductions in environmental impact.

Fusion’s complete service offering takes acustomer from design, throughmanufacture, and on to installation on site.The superior technical performance of theFusion products is fully certified and tested.

Fusion has significant experience in havingsupplied and installed building systems toover 5,000 buildings, ranging from carehomes and housing developments of up to700 homes to luxury six storey apartmentdevelopments to various hotels and even afive star hotel complex, not forgettingnumerous individual dwellings.

Our average contract value is around£550,000 ranging from £35,000 to projectsin excess of £2m, which clearly shows theflexibility of the product and themanufacturing process.

The key to success is the involvement ofthe Fusion “design team” at the veryearliest stages of a potential project. Thisenables us to work with our client andassess the realistic potential for the systemas a solution. Furthermore the vastexperience of the team simplifies the wholedesign/pre-con stage working closely withthe client and the clients architectsreducing design times and costs.

Our structural engineers are on hand atevery stage of the process from designright through to completion often initiallyadvising on the basic structure and then online loads optimising slab build up andcosts accordingly. Each project is then

516

For more information contact:

Emma Cade on tel: 01430 444504 or

Monika Kubacka on tel: 01430 444551

For more information on Caledonian visit:

www.cbuildings.co.uk

www.buildoffsite.com www.buildoffsite.com

European Hotel Brand of the

Year Award

Gateway Pods Limited, EuropeanHotel Brand of the Year

The design of a new brandprototype Holiday InnExpress for IntercontinentalHotels Group has won theprestigious Hotel Brand ofthe Year Award at theEuropean Hotel DesignAwards 2010.

ICA Architects designed the new HolidayInn Express bedroom suite, bringing inpods experts Gateway Pods to design andmanufacture the new bathroom. ICAcollected the award at The Sleep Event inLondon on behalf of the world renownedHotel group.

Using bathroom pods in hotel projects notonly saves the client time, but also reduceson site trades and waste with the certaintyof a guaranteed cost. Gateway Pods haspartnered with IHG Hotels in the supply ofhigh quality bathroom pods for over 12years.

Up to 10 Holiday Inn Express hotelsthroughout the UK have now been builtusing the award winning hotel room andbathroom design.

Yorkon builds UK’s largest

modular supermarket – an eco-

store for Tesco

Award-winning off-sitespecialist, Yorkon, hascompleted the UK’slargest retail project to bebuilt using modularconstruction – a new eco-store for Tesco atSoutham in Warwickshire.

Working closely with main contractors RGCarter, the Yorkon off-site approachreduced the build programme to increasethe number of trading weeks by eight to thebenefit of Tesco and its customers. Thearchitects for the project were the SaundersPartnership.

The scheme is the first application of a newmodular store design, which provides20,000 sqft of retail space, and hasuninterrupted spans for the sales areas of28m, which are unprecedented in themodular industry. This was achieved byreducing internal columns by 50 per cent.

In order to meet the deadline for the storeopening, 24-hour factory shifts wereemployed at the Yorkon production centrein York to manufacture and partially fit outthe 70 steel-framed store modules, and thecranage phase included both weekend andnight working.

Commenting on the project, LorraineO’Sullivan, Development Manager at Tesco,said: “From a customer experienceperspective, you cannot tell this is a modularbuilding. The over-cladding has been veryeffective and customers have been verycomplimentary about the new store.”

“Off-site construction allows more work tobe carried out in a manufacturingenvironment, improving both quality and

construction processes in order to bringdown costs and to deliver improved valuefor clients and customers. Certainly theUK’s regulations are well ahead of wherethings are in the US but we will catch upquickly just as you have been catching upwith leading EU and Scandinavian practice.

I believe that these developments and thedemands of the market place are going toserve as a real stimulus to the offsite sectorand it will make no material difference ifyour preferred material is timber, steel,concrete, a composite or more likely acombination of all of these. The ability toconstruct building components that willdeliver a high quality performance is alwaysgoing to be that bit more straightforward inthe controlled environment of a factory ascompared to a temporary construction site.Reducing levels of waste is also mucheasier to manage in a factory than on aconstruction site.

Improvingproductivity canreally only betackled by carryingout as muchconstruction as

possible away from the construction site. Ihave absolutely no doubt that the future ofconstruction is going to be offsite and incase you have any doubts about mycommitment just bear in mind that I am soconfident that I bought the company.

I am really pleased to have developedcontacts with the UK’s Buildoffsiteorganisations and to share ideas andlearning. In the US we don’t yet have theequivalent of a Buildoffsite, in that ourvarious industries remain silo’d, but we areworking on greater knowledge sharing andintegration to expand the idea of offsite toall sectors.

New member

ISG has joinedBuildoffsite as itrecognises thecontinuing importance ofoff site techniques indriving efficiencies andsustainability throughoutthe construction

process. Buildoffsite not only bringstogether a host of complementaryorganisations to share and develop bestpractice within the industry but also acts asa catalyst for future innovations andinitiatives within this dynamic sector. ISG isdelighted to add its support andexperiences, whilst positively contributingtowards the promotion and widerunderstanding of off site techniques acrossthe construction industry.

ISG is an innovative business and earlyadopter of off site technology across itsprojects within the UK and internationally.With over 2,000 staff, 28 offices and aturnover approaching £1bn, the businessworks with public and private owners,developers and occupiers across a broadrange of industry sectors. Within the UK,ISG focuses on construction, fit out andfood retail solutions, with a portfolio thatincludes numerous FTSE 100 companies,leading supermarkets, governmentdepartments and social housingorganisations. Internationally, ISG has astrong presence in mainland Europe, Asiaand the Middle East, and delivers high-quality project management and fit outservices for its multi-national client base.

4 17

For more information on ISG visit:

www.isgplc.com

….. reducing levelsof waste is much

easier to manage ina factory than on aconstruction site

…we don’t yet have the equivalent of aBuildoffsite but we are working on greater

knowledge sharing and integration.

For more information on the Miletus Group

visit: www.miletusgroup.com

To view a video of the new store and its

construction go to:

www.yorkon.info/tescosoutham

www.buildoffsite.com www.buildoffsite.com

Use of modular wiring systems inconstruction is something that although Ibelieve started off in the US has been takenforward in the UK as a technique for fasttrack installation of factory manufacturedand tested components. Certainly there is adiscipline involved in the installation of suchsystems but that seems to me to be a goodthing. There is also the point that using afactory made solution minimises materialwaste and also minimises the amount oflabour and supervision required on site,with the opportunity for a major uptick inquality. Adopting within construction thosepractices that are common place in othermanufacturing sectors seems to me to bean absolute “no brainer” and I really do findit frustrating that the US is not making moreuse of the practice.

In both markets there is increasing use ofpods and modular systems. In the UK youhave some really good manufacturers whoare producing quality product for a numberof market sectors where speed ofconstruction on site and an assurance ofbuild quality, delivery and price is absolutelyessential. I couldn’t help but notice that thehotel room I stayed in when I last visitedthe UK had been made in a factory... themajor tell tale was the fact that the serviceconnections had been designed to enablesimplicity of installation and connection andoh yes – the standard of finish was superb.

Helping clients to understand the businesscase for choosing an offsite constructionsolution is I suspect somewhat simpler inthe US where the client is likely to want tofocus on what we call the “financial proforma”. Put simply this involves us in beingable to give the client an absoluteassurance that by adopting offsiteconstruction solutions he is buying a fixedprice, certainty as to quality and a fixedconstruction time – no ifs and no buts. Theclient will understand precisely that they areassured that from a specified date, the

building will be ready to generate revenueand this certainty is then built into thefinancial appraisal of construction system.Clients are most unlikely to have this levelof certainty if they select any other form ofconstruction.

One very significant issue that requiresmuch more attention in both the US and theUK is the need for our workforce to betrained in the new skills and practicesneeded to get the most out of thetechnology advances possible through theincreased use of offsite construction. Forexample during their professional trainingyoung architects are taught very little ifanything about the integration of offsitecomponents with in situ constructionmethods. They are taught very little aboutdesigning for assembly and with greatregret I suspect that their training does notchallenge them to think of themselves asan integral and integrated member of theconstruction team. In my view this is amajor gap in US professional trainingpractices and it is one that the MBIEducation Foundation is seeking toaddress. I believe that much the samesituation applies in the UK. Perhaps this isan effort that would benefit from cross-county collaboration.

A development that is having a real impacton design and construction practice in boththe UK and the US is environmentallegislation and the drive for increasedsustainability. Perhaps the biggestdifference in approach is that in the US wehave an incredible number of differentregulatory systems that dictate minimumlevels of building performance dependingon the State and County Codes. At least inthe UK your regulatory systems are for themost part set nationally.

Both in the UK and in the US the drive is onfor the design of buildings and the buildingprocess to become much more efficient.The regulatory requirements and therequirements of leading clients will requireincreased efficiency in the form of energyrequired to run buildings. Moreover,economic factors will require more efficient

the speed of construction on site. Thisenables Tesco to be faster to market and toopen the doors of a new store to ourcustomers more quickly.”

As an eco-store, the new Southam schemehas a number of sustainability features toreduce its carbon footprint, including:

� roof-mounted photovoltaic panels togenerate electricity

� a high level of glazing to one elevationfor natural light

� sun pipes to the offices and toilets

� rainwater harvesting

� a lobby area to the main entrance withsliding doors to reduce heat loss

� timber cladding from sustainable sources

� mixed mode ventilation

� air scoops for additional ventilation.

The store design also includes back-of-house, staff facilities and officeaccommodation on the first floor, and hasconcrete floors with terrazzo tiling.

Yorkon has worked with Tesco for the past10 years, delivering around 200 projects,including more than 170 Expressconvenience and petrol filling station storesin the UK and Ireland, and is the marketleader in off-site construction solutions forthe retail sector.

Buildoffsite events

Buildoffsite breakfast briefings

Delivering enhanced client value:designing for manufacture andassembly

Context:Clients are looking to their advisers andsuppliers for fresh ideas that will helpdeliver the quality and sustainable buildingsthey require but at a significantly lowerprice and with assured delivery times.

This is a significant challenge and it isentirely likely that if the industry is to rise tothe challenge it will need to adopt newways of working collaboratively.

The practice of designing for manufactureand assembly has been adopted by otherindustries as a proven technique to ensureeffective and informed communication andcollaboration between those developing thedesign and those who will deliver thevision.

Designing for manufacture and assemblydoes not compromise the ability ofdesigners to demonstrate design flair andinnovation. However, it does require themand other members of the professionalteam to be prepared to be prepared to workmore closely with constructors andsuppliers to establish the optimum methodsto deliver the client’s vision whilstminimising risk.

The breakfast briefing:The breakfast briefing will featurepresentations from forward thinkingarchitects, constructors and suppliers onhow they are applying the principles ofdesigning for manufacture and assembly inpractice and the benefits for all that haveemerged. The speakers will be:

� Martyn Wood of Bryden WoodAssociates

� Anna Winstanley of Laing O’Rourke.

318

…. factory manufactured mechanical andelectrical installations are increasingly

being used in commercial andoffice developments

Date: Wednesday 9 March 2011

Venue: Buildoffsite, Classic House,174–180 Old Street, London EC1V 9BP

Time: 08.30am – 10.30am

Reserving your place: attending thisbreakfast briefing is free of charge forBuildoffsite Members. Non-members mayattend but a fee of £50 +VAT will apply.

Those wishing to book for this briefingshould contact Anna Whiting, Buildoffsiteon: anna.whiting@buildoffsite.com or tel:0207 539 3306.

www.buildoffsite.com www.buildoffsite.com

R&D breakfast briefing

Maximising R&D tax reliefWe all know that thebusiness environment atthe present time is verychallenging and theconstruction sector isunder particular strain.In these circumstancesno organisation can

afford to waste money or for thatmatter miss out on opportunities to recoverexpenditure where tax credits are available.An obvious concern is that constructionbusinesses should be taking maximumadvantage of the opportunities for R&D taxrelief.

Companies involved in the development ofoff-site solutions and other forms ofinnovation will be investing money inresearch and development but may not bemaximising the benefits available under theUK Tax system. This is your opportunity tofind out if you could be recovering more ofyour investment.

In support of its Members and GuestsBuildoffsite is pleased to host a specialBusiness breakfast briefing on MaximisingR&D tax relief featuring Gareth Edwards ofela. This is your opportunity to find out ifyou could be recovering more of yourinvestment.

Key issues:� exchange up to 24.5 per cent of your

losses for cash

� reclaim your corporation tax, or reducefuture liability

� immediately claim 100 per cent of yourcapital spend against tax

� claim for the last two years

� significantly enhance your existingclaims

� intellectual property – can now claimunder SME scheme even if IP not owned

� qualifying indirect activities – recentHMRC guidance can increase claims

� new minefield – HMRC guidance on“production” activities

� understand how the R&D tax regimeswill change (currently under discussion)

� get tax relief on revenue due to patentedtechnology (current proposal).

To find out more why not join us at ourBuildoffsite business breakfast…

Presented by: Gareth Edwards, ela8

Gareth Edwards is a life-long R&Dprofessional and entrepreneur, withextensive experience of putting togetherand supporting R&D tax relief claims for awide range of companies, frommultinationals to start-ups – gained whilstworking as a Director for the award-winningDeloitte & Touche R&D Tax Services group.He has presented at numerous publicforums on the benefits available, and howto set about claiming. His deep interest andinsight into technology means he can talkeffectively with your technologists, quicklyextracting the scope and basis for yourclaim and presenting this in a way that thetax authorities will understand and accept.

This workshop will feature:

� an introduction to R&D tax relief

� what activities and expenditure can beeligible

� examples of eligible projects

� question and answer.

and the job came in way below budget at$41m. So almost 80 years ago we wereclearly doing something right – somethingthat has worked brilliantly well as asustainable commercial project and as aniconic piece of construction.

The parallel ofwhere theeconomy is todayto how thingswere during theglobalDepression whenthe Empire StateBuilding wasconstructed is notlost on me.Perhaps we needthe stimulus of amajor economicchallenge to getpeople to step upa gear in terms oftheir willingnessto look beyond

the status quo for construction solutionsthat contribute a step-change in value forclients and customers.

The US housing market and markets suchas Canada have always had a very efficientmanufacturing and construction sectorharnessing the flexibility and cost benefitsof timber frame systems. We do of coursegrow a lot of timber in the US and Canada,and have been exploiting wood as aprimary building material since the firstsettlers arrived in the US in the sixteenhundreds. Wood buildings are incrediblypopular with US customers and very fast toconstruct on site from a basic set of factorymade components. In the housing marketthe US is already in large part committed tothe use of offsite solutions whereas for themost part the UK is addicted to new buildhomes mainly constructed using masonry.So the US tradition for timber frame ismatched in the UK by a long establishedtradition of brick and block construction.Both traditions have their establishedsupply chains that, of course, are verycomfortable but which in no way provides

any sort of incentive to spur those involvedto want to change to an alternative. Insteadalternatives such as the employment ofoffsite modular components are viewed asuntested and therefore full of potential risk.

Curiously in the UK I find that people seemvery reluctant – even hostile – to the use ofthe term “prefab” when talking about housebuilding systems. The reason has beenexplained to me but frankly I still don’t getit. In contrast, in the US in some circles totalk about “prefab” when describing newhomes built from a kit of quality factorymade parts is just about the coolest thingyou can do. There are even websitesdevoted to the topic. Who was it who talkedabout “two peoples separated by acommon language……?” The dichotomiesand similarities between the US and UK arereally quite fascinating. I recommend ColinDavies’ History of Prefab as providing asuperb overview of how the offsite sectorhas evolved in both countries.

So what is the UK doing that the US is not.I have been really impressed with the wayin which factory manufactured mechanicaland electrical installations are increasinglybeing used in commercial and officedevelopments and in other highly servicedbuildings such as hospitals. The deliveryand installation of large factory testedinstallations is still relatively unusual in theUS and I can recall a project delivered bySkanska that made use of such factory-made solutions to very good effect onquality and project efficiency and thatattracted some excellent publicity in thetechnical press. What also attractedinterest was Skanska’s establishment of amanufacturing facility alongside theconstruction site. A mobile factory, that wasa clever idea.

2 19

Empire state building

Colin Davies traces the history ofprefabricated buildings from small-scale“prefabs” to the precast concrete masshousing of the 1960s to the present-day.<www.amazon.co.uk/Prefabricated-

Home-Colin-Davies/dp/1861892438>

Date: Wednesday 15 June 2011

Venue: Buildoffsite, Classic House,174–180 Old Street, London EC1V 9BP

Time: 09.00am – 10.00am (registrationand refreshments from 08.30am)

Reserving your place: a notional chargeof £50 +VAT is payable for each delegateplace to cover administration costs. Thereis no charge for Members of Buildoffsite.

Those wishing to book for this briefingshould contact Anna Whiting, Buildoffsiteon: anna.whiting@buildoffsite.com or tel:0207 539 3306.

www.buildoffsite.com www.buildoffsite.com

Benchmarking best practice in

the offsite sector

Why is the Buildoffsite AccreditationScheme important to the offsiteconstruction industry?The answer is:

� it provides client organisations withgreater confidence of delivery to time,cost and quality through theimplementation of risk management bestpractice

� it provides management andshareholders with the assurance thattheir risk management, competencymanagement and configurationmanagement systems have beenindependently validated as meeting bestpractice with the attendant likelihood ofcostly mistakes minimised

� it represents a key element of theBuildoffsite Property Assurance Schemeand will facilitate a route to market forthe offsite provider with recognition ofthe scheme by all major lendersincluding RBS, Lloyd’s Bank, Santanderand Nationwide, together with RICS andthe valuer community.

HighlightsThe workshop will represent an interactivesession with opportunities for delegatedebate and discussion throughout.

Representatives from accredited offsiteproviders will deliver their perspective ofthe accreditation process – what it meantfor them in terms of investment and therealised added value

What will the participants gain fromattendance?The opportunity to discuss the BuildoffsiteAccreditation Scheme with both theaccrediting body and organisationsaccredited.

You will learn that we do not seek tointroduce new systems and processes butto work with those you have alreadyimplemented to achieve best practice.

The session will cover:

� an overall insight into the scheme, scopeand coverage

� the importance of an integrated riskmanagement system

� how risk management and configurationmanagement processes reduce thelikelihood of costly mistakes

� how an integrated risk managementsystem involves everyone in theorganisation and aligns everyone tocommon aims and goals

� how definitive competency matricesminimise variability of performance

� how the systems required by thescheme encourages communicationbetween members of the supply chain,minimising interface issues.

The use of offsite construction methods is agrowing phenomenon not just in the UK butalso across much of the Globe. Given theincreasingly international nature ofbusiness and the free flow of knowledgeand best practices this is hardly surprisingbut what do we really know about thedevelopment of the offsite market in othercountries?

In the first of a series of articles fromcontributors from around the world thefollowing piece gives a sense of how themarket for offsite is developing in the USand how practice over there compares withpractice over here. Our contributor isJames B. Guthrie, AIA, architect andPresident of the Miletus Group.

James is also an entrepreneur with amission. He has established the MiletusGroup as a designer and manufacturer ofoffsite construction systems. He made thismove from traditional on-site buildingpractices because he was not satisfied withwhat the market had to offer and wanted todevelop better solutions. James is a great

enthusiast for modularbuilding techniques as ameans to achieve realarchitecture. He saysbest results are achievedwhen excellence indesign is close-coupledto expert knowledge ofconstruction practice.James also has a strongcommitment to thedevelopment of skills within his industryand advancing new knowledge. He iscurrently chairman of the US ModularBuilding Institute’s Education Foundation.

A message from America

I visit the UK several times a year onbusiness and also to keep up to date withdevelopments in offsite solutions on yourside of the pond.

People often ask me if the US market foroffsite solutions is more advanced andmore sophisticated than the market in theUK. When they ask this question I get areal sense that the expected response hasto be that in the US we are years ahead ofyou Brits. The fact is that generally we arenot. Indeed in many ways the UK is farahead of us in terms of the range of offsitesolutions offered and which in manymarkets are becoming quite commonplace. Why this should be took me sometime to understand. The US led the waywith the development of modernmanufacturing methods and the move tomass production and construction. Mostpeople are unaware that back in 1931when the Empire State Building wasconstructed that it was, in part,manufactured with large scale structuraland cladding components delivered to siteusing what we would now describe as “justin time” practices. Assembly of large scaleprefabricated components was the onlyway to construct a record breaking buildingin the time and to the budget set by theclient. The construction time wascompressed into just one year and 45 days

February 2011

1

Richard Ogden,Chairman

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James Guthrie – a man witha mission

Dates: Tuesday 5 April 2011 andWednesday 21 September 2011

Venue: Buildoffsite, Classic House,174–180 Old Street London, EC1V 9BP

Time: 08.30am – 10.00am

Delegate places at this event are free –on a first come first served basis

Presenters: Nick Whitehouse,Buildoffsite, Simon Wood, Britspace andTerry Mundy, Lloyds Register

To register for this workshop contact AnnaWhiting, Buildoffsite on email:anna.whiting@buildoffsite.com or tel:0207 549 3306.

….. best resultsare achieved

whenexcellence in

design isclose-coupled

to expertknowledge ofconstruction

practice.

www.buildoffsite.com www.buildoffsite.com