Modular Makes Sense

 

From schools and colleges to hospitals and prisons, modular buildings using modern methods of construction can offer high quality, cost-effective space solutions to both short and long term needs.

 

 

Modern methods of construction (MMC) first came to the fore sixty years ago in the form of prefabricated bungalows to address the housing shortage after World War II.  Established in 1949, Terrapin was at the forefront of these developments and the company evolved the 'folding' building unit concept along with the associated requirements to produce such units in the factory on a flow-line basis. In the 1950s the company developed the Mark 36 - a factory manufactured structure that was a complete classroom building unit. This unit provided much needed extra accommodation in UK schools during the 'baby boom' and at the height of construction a Mark 36 was leaving the Terrapin factory every 20 minutes. During the 70s modular systems were advanced to combine the strengths of traditional build with the introduction of new steel framed design and build technology. So MMC has a long established history in meeting public building demands and that successful association still continues today.

 

Offsite construction has come a long way since those early days and the latest technologies are now at the leading edge of modern public building programmes. Modular systems offer the benefits of a variety of offsite construction methods to suit permanent and re-locatable building requirements, including panel based and steel-framed based construction systems. Modules that are fully compliant with stringent energy efficiency and insulation standards can be built and fully fitted offsite, and engineered to incorporate features such as anti-vandal protection, data networks, air conditioning, rainwater harvesting, solar collection and shading systems, to name but a few. Developments in modular production capabilities and complementary services, including design, planning, finance and rental options have extended the scope of offsite construction to all sizes and types of public building procurement.

 

Given the cost- and time-saving benefits, offsite construction is regarded as one of the key means of meeting the Government's new build and refurbishment programmes in areas such as healthcare, education and prisons. Significant advantages over traditional build include the speeding up of the procurement and build process and a higher level of quality assurance on building modules produced in factory conditions. In the education sector, for example,  modern modular structures can provide permanent buildings and also re-locatable 'decant' accommodation whilst new build or refurbishment works are carried out as part of the Government's Building Schools for the Future initiative. With this specific need in mind, Terrapin has recently launched two economical, high quality double classroom 'products' - a short term hire version and an enhanced specification version for longer term hire or outright purchase. Both options provide two teaching areas – each with a store – and a communal entrance and comply with relevant building and fire regulations. The new classrooms embody the proven benefits of factory-built structures, including far less disruption on site than traditional methods, fewer deliveries, less noise, mess and waste and lower risk of theft or vandalism.

 

In the healthcare sector, primary care has become the main focus for the NHS and this is driving the expansion of facilities such as walk-in clinics and treatment centres through the NHS LIFT procurement programme. In the current economic climate there are question marks over many healthcare building projects that are still at the planning stage. Modular buildings offer an ideal solution to budgetary pressures, delivering high performance healthcare facilities faster, to a high standard and at lower cost. There is also the option of hiring factory-built buildings to provide effective new treatment or working space for the healthcare sector. Typically, an air conditioned Terrapin building can be ready for occupation within a few weeks of ordering – with rents from as little as £8 per square foot, and flexible rental periods from one to 10 years. In healthcare applications further savings are possible if the rented building is part of a fully serviced package from a facilities management company. The savings come because the rent is financed through the operating budget rather than the capital budget and may, therefore, be exempt from VAT. The prefinished elements that go to make up a permanent or re-locatable building - such as walls, staircase modules, or even complete rooms - can be pre-manufactured off site, under factory conditions and then rapidly assembled on site - meaning less disruption in terms of access, noise, dust, dirt and a reduction of risk in terms of health and safety.

 

A rising prison population has led to a corresponding rise in the number of construction orders for HM Prison Service. From 'flat pack' buildings to volumetric units and steel frame systems, offsite building solutions can offer a fast, secure and flexible response to the Government's Capacity Programme, which aims to provide 20,000 new prison places by 2014. Terrapin has developed a factory-built custodial unit - a modular building solution that has already been used to complete a number of fast track prison projects. Custodial modules can be designed to meet individual project needs, including cells, activity areas and canteens, and can be fitted with features such as anti-vandal protection, data networks, air conditioning and solar energy systems.

Offsite construction is ideally suited to the challenges faced by today's public building specifiers, offering shorter construction times, sustainability and value for money. Techniques and materials have certainly advanced since Terrapin's early projects sixty years ago, but the benefits of the concept of factory-built buildings are as compelling as ever and Terrapin will continue to push the boundaries of modular building design to meet the needs of tomorrow's public buildings.

Offsite Methods Answer Healthcare Challenges

Matching requirements to often limited resources is a constant challenge for the modern healthcare sector. Building new hospitals or updating existing facilities is vital to increase the quantity and quality of primary and secondary care in line with demand, but can be costly and disruptive. Modern offsite building technology can play a key role in helping healthcare managers achieve higher value for money and the flexibility to relocate or reconfigure facilities to meet changing needs.

 

Making cost savings whilst delivering on government priorities, such as giving patients more choice and reducing waiting lists, may seem like an impossible task for today's cash-strapped NHS. Modern methods of construction can provide a solution to this dilemma in the form of high quality healthcare facilities, faster and at lower cost. The elements that go to make up a permanent or relocatable building - such as walls, staircase modules, or even complete room modules - can be pre-manufactured offsite, under factory conditions, and then simply assembled on site. Because the production methods are controlled, high levels of accuracy and fit-out quality can be achieved.  This is particularly important for higher specification facilities such as operating theatres. It also means reduced time on site and less disruption in terms of access, noise, dust and dirt, another key issue for healthcare environments.

 

Facilities built offsite can range from a complete new hospital to clinics, mental health units and GP surgeries. The design can also incorporate office space, living accommodation, communal areas and secure zones. One of the most obvious advantages of offsite construction is that it is quicker than using conventional building methods, with less waste and minimal onsite reworking. This saves time and cost and means facilities are available to patients sooner. The modular approach also guarantees that the project will be completed on time and on budget.

 

Terrapin was one of the pioneers of offsite construction, and in the years following the Second World War it was able to meet the needs of post-war reconstruction with high quality buildings at low cost - without compromising good architectural practice. In the current economic climate, high building demand is combined with cost pressures and the environmental drive to reduce waste. At the same time, the demands of building regulations (as incorporated in HTM and HBN documents) have become tighter. The requirements in terms of, for example, thermal and acoustic insulation have become much more demanding. The combination of all these factors means that Terrapin's approach is more relevant than ever across a wide range of sectors, including healthcare.

 

By building offsite Terrapin can ensure that the highest levels of thermal and acoustic insulation are an integral part of the fabric of the building. Special facilities, such as clean rooms, can be delivered to site ready to go into service. For operating theatres and ICUs, for example, provision for services can be built in at the design stage and access provided for long term maintenance.

 

Offsite construction also allows pre-engineered buildings to be erected on extremely tight and difficult sites – even on top of existing structures or as infill constructions. This allows the site to be used to its maximum capability and means there are no restrictions on putting facilities where they are most appropriate - offsite modules can also be relocated or reconfigured as requirements change.

 

There are also environmental advantages. On conventional building projects every element that goes into the building is delivered separately and comes in its own packaging – from paint tins to shrink wrap on masonry blocks. At the end of a project excess materials are often just sent to landfill because 'they've already been paid for by the client' and it is easier than sending them back. Manufacturing under factory conditions allows for efficient materials usage, more effective recycling, reduced packaging and less energy used to transport the building materials to the site.

 

To meet the varying demands of different types of healthcare project Terrapin has developed expertise in three different and complementary technologies; flat wall or floor panels, modular (or volumetric) elements or steel-framed elements.

 

The panel-based approach is based in timber-framed panels with an internal lining of foil-backed plasterboard and can come with a choice of external cladding materials. This approach uses proven materials and factory fabrication techniques that allows flexibility in the design and a high quality of construction, combined with value for money and speed of construction. Typical applications could be GP surgeries, outpatient clinics and nurseries.

 

Modular units are built with a steel frame and are ideal where the requirement is for a large number of standard units – such as bedrooms, and bathrooms. Complete modules are manufactured and fully fitted out at Terrapin's factory and quickly assembled on site with all service connections already in place – fixed furnishings, sanitaryware and decorations can also be built in at the factory.

 

Finally, combining hot-rolled fabricated sections and cold-rolled galvanised beams, steel framed element-build technology gives design flexibility for unique buildings but still allows the benefits of factory fabrication projects from stairwells up to and including complete hospitals - indeed, complete, cost-effective solutions to meet healthcare needs now and in the future.

Is it all about the money

The offsite industry needs to demonstrate the peripheral cost benefits of an offsite solution. For example, can it bring an earlier benefit from a revenue stream as a result of a shorter build programme? Will there be less downtime / disruption as a result of factory guaranteed quality control? If these are fully considered then an offsite solution can be the most cost effective approach, even though the initial capital cost may (in some instances) be slightly higher.

 

Offsite does not pretend to have all of the answers but it does provide a greater degree of cost certainty and can offer solutions that are not typically available from a traditional build provider, such as hiring or leasing options.

 

see www.terrapin-ltd.co.uk for the options available.

Modular Building pre-conceived myth

Offsite construction techniques have advanced significantly since the initial concept and today’s modular systems bear no resemblance to the prefabricated buildings of the past. Customers are now more open-minded about the concept and offsite technology is certainly no longer confined to the boxed approach temporary accommodation. Modern systems are designed to look good and, because of the flexibility in the construction methods and available financial options, are now acknowledged as real alternatives to the ‘traditional’ approach. Available as permanent or re-locatable solutions, according to the customer’s needs, today’s offsite buildings are fully compliant with the UK’s stringent building regulations, energy efficiency, thermal and acoustic insulation standards, and frequently incorporate sophisticated environmental control systems, data networks, rainwater harvesting, solar collection and shading systems.

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Benefits of Off-site Construction

 

·         opportunity to build a prototype before the full build commences

·         cost certainty

·         shorter and more predictable construction programme

·         improved health and safety

·         less disruption to site and local residents

·         fewer deliveries and less waste on site

·         greatly reduced snagging

·         fewer materials on site means less storage space required, less product damage, and fewer thefts

·         construction schedule is less weather dependent

 

Environmental Benefits of Modular Construction

Utilising modular construction naturally removes a lot of the site activities which can be inefficient and wasteful.  In the factory we are able to utilise just in time procurement methods with materials that are purchased in standard cuttings which is why Terrapin have been able to reduce the amount of waste produced by over 50% in the past 5 years.  In a true volumetric production process up to 70% of the building can be manufactured in the factory and delivered to site on the day of erection.  The benefits of adopting this method not only reduce the personnel activity at site but also accrue a significant saving in preliminaries.  The saving happens due to the quicker construction which in turn means that there are less deliveries to site and items such as containers and skips do not have to be let for long periods of time.

 

It is dissapointing that BREEAM does not take account of the benefits in adopting a method of construction which diverts a lot of the traditional environmental damage away from site.  A recognition of the wider environmental benefits of producing buildings in factories should surely be incorporated into the environmental assesment?

 

World's Ugliest Buildings

 

It was interesting to see today that number 7 in the Alexa (www.alexa.com/hoturls) what’s Hot list is the “World’s Ugliest Buildings” at Yahoo http://travel.yahoo.com/p-interests-30322161 .