Offsite - The Dating Game

The Offsite Dating Game!

Successfully exploiting Offsite construction is still seen by many architects and contractors as bit of a lottery, however it doesn’t need to be like this. Appointing and working with an Offsite partner should bring significant benefits to the build project provided there is a mutual understanding of the process issues and selection criteria critical to both sides. Martin Goss, MD of Mtech Consult, identifies the issues that really make the difference between success and failure.

The single most important issue for the project team to take on board as they plan to use Offsite construction is that the project process will not be the same as a traditionally procured build project. While this might sound blindingly obvious, it still surprises me how often this simple fact is ignored.

So why does it need to be different? Well, for one, manufacturers of Offsite construction systems are not contractors. Continuity of workload, forward planning & forecasting, collaborative design and long term product development are critical to the Offsite manufacturer with a large factory overhead and an extensive full time workforce.

But before we even think about which Offsite supplier is the best match for any project, there is a series of prerequisites that we need to have in place.

Offsite build strategy

Firstly we encourage the project team to develop a build strategy that optimises onsite construction activities. This direction document should identify if and what Offsite typologies are right for the project; it should establish the project drivers and constraints and create a framework or process enabling the project team to reliably establish the best fit Offsite systems. Both Loughborough University and Mtech Consult have developed online tools to provide a simple, structured methodology that project teams can use as the basis for system selection, see http://www.lboro.ac.uk/research/immprest/introduction.htm & www.mtech-consult.com.

With one or two exceptions – most noticeably Kingspan (with their Kingframe systems) and Elements Europe who are gearing up to offer a broader range of Offsite solutions – Offsite manufacturers rarely supply more than one system or typology, so it is clearly important that the system selection activity is complete and thorough at this stage.

Procurement route

Agreeing the build strategy and the role of Offsite is just the start of the process. The next key step, before we can select the right Offsite manufacturing partners, is to understand the impact the procurement route for the project will have on the use of Offsite technology. In our experience over the past 15 years, the procurement approach can significantly affect the choice of manufacturer and typology. Construction innovation using Offsite techniques works best when there is a culture of partnering and long term buy-in to the factory process; given the recession, framework procurement is not currently in vogue, but this partnering approach does deliver better Offsite in the long run. It allows the Offsite manufacturer to be appointed earlier in the process and thus support and guide the integration of the Offsite technology into the building design at the earliest possible opportunity.

Of course this is not always possible. If more traditional procurement methods such as single point tendering, D&B etc. are used, then the use of Offsite techniques will be more prescriptive and proprietary rather than innovative. In this traditional approach it is essential that the building design, whether at RIBA stage C, or D/E in the case of single point tendering, has been developed with the selected Offsite technology in mind. This places significant pressure on the design team to fully understand the chosen technology and design the building accordingly. Historically this is where Mtech Consult has been brought in to advise the project team, helping ensure that the tender design is Offsite compliant. When the tender pack arrives with the selected Offsite manufacturers it is essential that the design works efficiently for that Offsite system and manufacturer. If it doesn’t, at best it is likely to be a wasted tender enquiry and at worst, a construction project failure in the making.

An Offsite enlightened cost plan

The final step in the journey to intelligently exploit Offsite is a project cost plan that is sufficiently robust and ideally Offsite enlightened: it needs a level of detail that will assess the full cost impact and benefits of the selected Offsite technologies. Offsite techniques will change many of the standard elements that the traditional cost planner would automatically include; the changes required may not have previous cost history to draw from, making it difficult for the cost planner to anticipate an accurate outturn cost. Input at this point from the Offsite manufacturer or an Offsite specialist will be critical to assembling a reliable and robust project cost plan.

Project team expertise

Creating this informed project cost plan demands Offsite expertise and knowledge from within the project delivery team. We always recommend that the project principle assesses the level of Offsite knowledge within the team; whilst any deficit in expertise can be supplemented by specialist consultants such as Mtech, it is clearly good to have Offsite experience at the appropriate levels within the wider delivery team to minimise the risk to the project.

So now we have all the key prerequisites in place to make Offsite a success for the project. This may seem a long, arduous process, but in truth it is mostly about changing the culture and the way we work as a project delivery team for the better.

Offsite manufacturer selection

All professional project teams will have a well developed methodology for selecting system suppliers and contactors. This excellence in due diligence and supplier verification is absolutely necessary for the Offsite sector; however, there are some additional key features needed to ensure the project team gets the best possible Offsite manufacturing partner.

So, what are the key ingredients for successful selection?

q Typology relevance: It is clearly important to match the Offsite typology to the manufacturer. The simplest way to do this is to use our online directory (www.offsiteonline.co.uk), which provides a search tool to quickly get you a reliable short list of Offsite manufacturers matching your project criteria. It includes all the recognised Offsite manufacturers operating in the UK, over 1,000 separate entries.

q Scope of service: Each manufacturer will tend to offer slightly different levels of service, from sub-contract manufacture only through to a complete turnkey developer role including funding. Whilst the offsiteonline directory answers basic questions regarding scope, this needs to be thoroughly checked direct with the manufacturer. If there is any doubt about their capability, always ask to visit a previous project to verify that they can provide the level of service you require.

q Size of project: This is important at both ends of the spectrum. The rate of demand for the Offsite elements needs to be matched to the manufacturer’s production output capability. A small manufacturer may start manufacturing early and buffer-stock the Offsite elements, but this can create problems with storage and late design changes. Equally, larger manufacturers may be influenced by a client with a very large order at the expense of the smaller project.

q Standard or special: It is important to match manufacturer capability to deliver customisation with the level of variety and unique requirements of your project. A high volume manufacturer may find it difficult to deliver highly bespoke Offsite; a smaller manufacturer may not have the right management systems in place to reliably control the special product solutions through the production process.

q Product Certification: Whilst compliance with Building Regulations should be a minimum requirement, ideally recognised product accreditation such as BBA or BRE should be in place where the Offsite product involves unique design features. In some cases the manufacturer can provide insurance backed warranties which obviously provide greater reassurance for the more innovative Offsite systems.

q Location or system certification: Location of the factory is rarely a big issue. In our experience, transport cost and environmental impact are not key issues, however good logistics control is. Make sure the manufacturer has the ability to manage and control this aspect of delivery and site installation. Contract project management capability and systems such as ISO9001 QMS, ISO14001 EMS and ISO18001 OH&S are good measures of a competent manufacturer.

Clearly this check list is not exhaustive, but it should give you a good start point and remove some of the lottery nature of selecting your Offsite manufacturer. As we said at the beginning, Offsite manufacturers have typically invested heavily in their operation and need long term partnerships to make their business model work. Thus the incentive to provide service excellence is inherent in all Offsite manufacturers.... which can only be good for the success of your project.

Mtech Consult Ltd: 01743 282 282; www.mtech-consult.com

Press contact for Mtech Consult:
Clare Westbrook,Elixir Marketing, Cae Grove, Llanfair Green, Abergavenny, NP7 8PA, UK
T: 01873 821359, F: 01873 821462, M: 07702 369936, E: clare@elixir-projects.co.uk

Or for consultancy/technical information:
Bob Mears, Mtech Consult, Maple House, Shrewsbury Business Park, Shrewsbury, SY2 6LG
T: 01743 282 282, F: 01743 282 286,E: bob.mears@mtech-consult.com,www.mtech-consult.com

For Kingspan:
Sam Franklin, Kingspan (Steel Profiles and Sections) Limited
T: 0121 776 5460, E: sam.franklin@kingspanoffsite.com

For Elements Europe:
Victoria Scales,The Pickstock Group, 155 Grays Inn Road, London, WC1X 8UE
T: 020 7278 3832, E:victoria@thepickstockgroup.com,www.elements-europe.com