MMC solutions- such as offsite fabrication- could help the supply chain meet ever-increasing targets of efficiency and sustainability, says Adam Cafer, Advantage service manager at drainage and supply systems manufacturer Polypipe Building Services
Contractors are under pressure to deliver buildings more quickly, sustainably, at lower costs and with increased efficiency and environmental performance- and offsite fabrication could be the answer.
In 2017 the UK Government announced it would use its purchasing power to drive modern methods of construction(MMC) across capital projects, while its aim to get 300,000 new homes built per year by 2030 to fix a broken housing market demands a new way of building homes as the labour force to deliver it simply isn’t there.
MMC becomes more mainstream every year
While other countries, including Germany and Japan, have embraced modern methods of construction for years in the UK it has struggled to leave the starting blocks. However, the completion of the tallest modular building in the world – a 44-storey steel frame tower in Croydon in October 2022 – demonstrates confidence is growing in building in this way and is set to become more mainstream.
Various approaches fall under the MMC label – modular builds, component prefabrication, and pre-assembly, and it is offsite fabrication we have focussed on exploring at Polypipe Building Services in relation to providing drainage and water supply systems which support more efficient modular projects.
This approach delivers efficiencies in labour and costs while achieving a high-quality product. Working in this way also minimises safety risks associated with working at height, welding and cutting as these tasks are reduced. It is for these reasons that we anticipate it will be a fast-growing area in the coming years.
Offsite fabrication is suitable across residential, commercial and infrastructure projects
Key to this success will be the ability of manufacturers to ensure they have the technical capabilities in-house to allow for full offsite fabrication of systems to meet the specifications of different projects. We have supplied bespoke off-site fabricated products for various commercial applications, including healthcare, student apartments and hotels.
In a flagship project in Manchester, the customer wanted fabricated stacks for bathroom pods before they were installed on-site. Because we were involved early in the process, we were able to produce a test drainage stack they could take to their pod manufacturer to ensure the right fit.
We have found that materials such as high-density polyethylene (HDPE) are ideal for this purpose because it offers greater design flexibility than traditional materials to address specific challenges. This resulted in significant time savings as it meant the 20 pods needed per floor could be connected in about half a day compared to traditional methods which would have taken a week to install.
Enabling social value and sustainability
Another advantage to this process is that testing of the entire system can be completed in the controlled environment of a factory, reducing the need for specialist teams to be present on-site to do this and undertake significant work to install them at a time of rising labour costs.
By moving the construction process off-site, it is possible to provide secure, stable jobs in low-growth areas of the economy for workers unable to enter skilled sectors while also opening opportunities for skilled design and engineering roles.
Modern methods of construction also support a lower carbon footprint within the sector as tailor-made systems decrease the amount of waste generated as well as minimise transport emissions as there are fewer lorry deliveries, benefiting those people living nearby through less noise, pollution, and disruption.
Collaboration is key
Fast turnarounds, quality products, efficient and predictable costings and use of materials make it easy to see why offsite construction is being adopted more and more. The challenge we have faced – and one which will become more important to overcome as MMC projects increase – is to ensure we have early engagement in projects so we can collaborate more effectively with contractors to provide a solution that fits their specific project demands.
Collaboration across the complete supply chain and across projects will ensure we find the best solutions to our existing challenges – and those which are yet to come.
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