Modular Practices & Prefabrication: Yesterday, Today

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Modular Practices & Prefabrication: Yesterday, Today & Tomorrow

Bernie Sublette

Vice President

AECOM Hunt

Don Page

Director of Engineering

Good Samaritan Hospital

Kurt Stahl

Chief Operating Officer

Wurster Construction

Speaker Introductions

November 8th, 2021

Midwest Healthcare EngineeringConference & Trade Show – 11/8/21

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Purpose

CleanSuite Modular Operating Room Ceiling

• Evaluate The Approach, Benefits, and Constraints to Leveraging These Tools

• Cover All Phases From Pre-design/Planning, Design Considerations & Post-Design

Manufacturing & Installation

• Explore The Risk & Reward of Implementing Modular Practices & Prefabrication

Understanding the

need for early

adaptation by the

Owner & Designers

which stands in stark

contrast to traditional

“design-bid-build”

construction delivery

practices.


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Primary Resources

1) 2020 Updated Dodge Analytics SmartMarket Data

2) AIA Design for Modular Construction - Industry Guidance/Education

Modular Design + Fab Shop – Steel Volumetric Frames, Fort Worth, Texas


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1) SmartMarket Report – Dodge Data & Analytics, 68 Page Report

2) 2020 Report is a Follow Up to The Original 2012 Study

3) Purpose of Studies:

a) Current Status of The Market

b) Crystal Ball - Forecasting Likely Future

c) Share Case Studies

d) Identifies Both Benefits & Challenges

e) Factors Driving Growth & Expanded Use

Primary Resource 1 – 2020 Updated SmartMarket Reporthttps://www.construction.com/toolkit/reports/prefabrication-modular-construction-2020


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1) Respondents Agree Prefab & Modular Provide Significant Benefits

2) Users Forecasting Expanded Use of Both Approaches Over The Coming Years

3) More Data Available Now to Validate The Processes

4) Owners More Comfortable With The Process & Outcomes

5) Industry Has More Resources to Support Prefab & Modular

SmartMarket Report - Summary of Findings

“SmartMarket Report, Dodge Analytics, Prefabrication & Modular Construction 2020”

Vertical MEP Chase by Brandt Mechanical, UHS Hospital – San Antonio, TX


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1) An Introduction For Architects, 41 Pages

2) AIA Publication

3) Historical & Educational Data

4) Case Studies

5) Also Identifies The Barriers & Benefits

6) (3) Phases of the Modular Journey:

a) Pre-Design

b) Design

c) Post Design

7) Glimpse Into The Future

Primary Resource 2 – Design Industry Guidance/Educationhttps://content.aia.org/sites/default/files/2019-03/Materials_Practice_Guide_Modular_Construction.pdf


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What – What is Prefabrication & What is Modular Construction?

Why – Why Should We Be Considering Prefabrication & Modular Construction?

How – How Do We Plan, Design, Procure & Install?

Who – Who Are The Players?

Where – Where Does Prefabrication & Modular Construction Occur?When – Expected Milestones & Timing of Key Events?

OR Ceiling System by Flexible OR Solutions – Dripping Springs, TX

Presentation Format


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Prefab in Healthcare Setting – Penn First Pavilion (YouTube)


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WHAT

Prefabricated Bathroom Pod & Headwall for hospital patient room – Atrium Health, Charlotte, NC


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Design for Manufacture and Assembly

1) Should be Initial Approach to Design

2) Two Methodologies

• Designing for Ease of Manufacture

• Designing for Ease of Assembly

3) Facilitates Duplication/Repetition of The Product

4) Reduces Cost of Manufacturing & Assembly

5) Drives Out Waste or Inefficiency

6) Lean Practice

DfMA Process Defined

BIM Model - Prefabricated Bathroom Pod


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1 - Volumetric - 3 Dimensional Units of Enclosed Space

a) Bathroom Pods, Patient Rooms, Elevator Sections,

Stair Cores, Skid Mounted MEP Units

b) Can be Structural or Non-Structural (i.e.BLOX, Modular

Design +, DBC)

c) Recent Years Structures Have Exceeded 10 Stories

d) Stack Like Legos

2 - Non-Volumetric

a) Sections of Flat Building Façade & Cladding

b) Wall Panels & Interior Partitions (i.e.DIRTT, Falk Built)

Volumetric Definitions – (2) Types

Volumetric Construction

Non-Volumetric Construction


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1) Multi-Trade Prefabrication (left image)

a) Work Out of a Common Shop

b) Unit is Framed, Sheathed, MEP / FP / LV, Med

Gas, Insulation, Etc.

2) Single-Trade Prefabrication (right image)

a) Curtain Wall - Example Far Right This Page

b) Pre-Glazed Units Ganged Together, Hoisted Into

Place

Multi-Trade - Utility Tunnel MEP Racks Lowered Into Place at UTSW Dallas

Single Trade - Unitized Curtain Wall System

Trade Involvement


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Most Likely Type - High Frequency (All Respondents)


643


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Most Frequency of Prefab By Type (Per Respondents)

GC’s / CM’s


Trades


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Why Healthcare? Many Possibilities

Curtain Wall

Stair Core

Patient Bathrooms

Flex Headwall

Clinical/Exam

Room

OR Ceiling System

Uber Modules MEP Corridor Racks

OR Wall System Utility Tunnel Racks Clinical/Exam

Room

Exterior Facade

Interior Wall Systems

Med Gas Manifolds

MEP Chases

Scrub Sink Module

Others:

Emergency Dept, Nurse

Observation Units,

MDF’S, Elec. Rooms,

Elevator Cores, Etc.


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Respondents Forecast For Increased Use of Prefab/Modular


1 2 3 4


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WHY


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1) Facing Shortage of Skilled Labor (Probably #1 Reason)

2) Need to Reduce Cost of Construction

3) Speed To Market - Shortened Durations

4) Advancements in Technology - BIM, CAD/CAM/CNC*

5) Ability to Improve Safety & Lessen Risk

6) Able to Produce Higher Quality Results

7) Seeing Exponential Productivity Gains

Headwalls Being Prefabricated on 12th Floor Shell Space at UTSW Dallas

*CNC (or Computer Numerical Control) Precision Machining is a widely used technique for producing a variety of complex parts and components with a high degree of accuracy.

Factors Driving The Use of Prefab


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1) Construction Industry is Projected to Grow 12% By 2026

2) BLS Says “Faster Than Average Job Growth”

3) Normally Great News, But …….

4) Detrimental Imbalance – Worker Demand Versus Available Labor Supply

5) 78% of Construction Companies Struggle to Fill Salaried & Craft Positions

6) Skilled Workers Retiring Out of Their Positions (Boomers)

7) Young Talent Not Available to Step up in Their Stead

8) Over The Past Decade, Construction Companies Have Struggled With

Developing Interest in Trade Work

Shortage of Skilled Labor – National Crisis

“White Paper – Modular Building Institute (MBI)”


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1) Concern Over Shortage - Top Driver For Prefab Per GC’s/CM’s

2) Focus is on Modular Construction’s to Combat Workforce Shortages

3) Less Challenges Now - Prefab Industry is Maturing Rapidly

4) Moving in This Direction for Survival … Major Construction Companies &

Design Firms Are Buying Prefabrication Shops & Modular Building Plants

5) Workforce Shortages Are Counterproductive to The “Need for Speed”

Shortage of Skilled Labor – National Crisis


“I feel the need, the need for speed”


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1) Using Precision Tools – BIM, CAD/CAM, CNC, Jigs, Lifts, Conveyors, etc.

2) Building & Storing Product in an Enclosed Facility

3) Work is Protected From Elements

4) Less Exposure to Weather, Less Moisture Related Damage

5) Result: Increased Durability of Project Components

Quality Gains

BLOX Manufacturing Plant – Birmingham, AL

Digital Building Components – Phoenix, AZ


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Productivity Per Industry

Charting productivity 1950-2012

manufacturing

construction


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1) Space Designed for Ideal Conditions to Manufacture2) No Impact From Adverse Weather

3) Precise/Advanced Tools & Machinery

4) Crew Workday (Hours) is Longer Than The Field

5) Less People - Same Amount of Work

6) Mistakes in Field Vs. Mistake in Shop

7) Inspections in Shop Vs. in Field

Improved Productivity

Exterior Wall Panel Receiving a Window at Baker Triangle Prefab Shop – Dallas, TX

Unknown Construction Worker That Cannot Feel his Fingers – Somewhere, USA


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1) Controlled Setting, No Hazards of Extreme Weather

2) Noise & Air Quality Improved

3) Much Less Ladder & Scaffolding Work

4) Lighting is Better

5) Cleanliness Better Than Jobsite

6) Rates for Injuries Substantially Lower In Manufacturing

Setting (U.S. Dept. of Labor) Than in the Field

Enhanced Safety

Prefabricated Utility Bridge - Good Samaritan Hospital Vincennes, IN

Acme Prefab Shop – No Longer in Business

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1) Concurrent Workflows for Off

Site & On-Site Activities

2) Build Prefab While Foundations

Are Being Constructed

3) Supply Chains – Distinct From

Field

4) Added Certainty is Better Than

Cost Savings

Shortened Schedule


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Impact of Prefab From 3 Points of View –

Winner: Productivity

Architects GC’s / CM’s Trades

1 2 3



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HOW


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Utilize a Playbook – Manufactured Components

1) Basic How to Guide

2) Removes Ambiguity, Assigns Roles & Responsibilities, Reduces Variables & Unknowns

3) Provides Guidance When Manufactured Components are Integrated into a Project

4) Provides Work & Process Flow, Process Definition & Instructions for Tasks Performance

5) Basis for Standardization & Ongoing Process Improvement

6) Flow Based on Phases of a Project: Planning, Design, Pre-Construction, and Construction

7) Updated & Versioned Regularly


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Engaging The Modular Process Early (The Grid)

Applying the grid to MEP Corridor Racks

Establishing & Applying the Grid


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Engaging The Modular Process Early (Timing)

1) Finalize Strategy at 50% & 100% Schematic Design

2) Loose Ability to Leverage Benefits at Later Stages

3) Fundamental Shift in Design Responsibilities

4) Prefab Consultant Experienced With Complexities of Modular Construction

5) Structural is First Critical Element

6) MEP Corridor Racks – Effect to Structure (Example at Right)

Structural Considerations for Corridor MEP Racks at Mount Carmel

Plan View

Section View


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Engage Modular Manufacturer

1) EARLY Consultant Engagement Yields:

a) Flexibility in Design Options (Kit of Parts)

b) Avoid Outdated Spec’s

c) Avoid Specs Requiring Long Lead Mat’ls /Products

d) Value Engineering (Real Time Market Expertise)

e) Control & Reduction of Transportation Costs

f) Constructability of Design

g) Efficiency & Improved Waste Reduction

2) Clearly Establish Specific Scope of Modular Manufacturer (Including

Design Demarcation)

3) Scope Cannot be Vague Regarding Responsibilities

4) Solid Expectations Are Required

Prefabricated Exterior Wall Panels at Baker Triangle Fab Shop – Dallas, TX

Prefabricated Exam Rooms Rolling Out of BLOX Fab Shop – Birmingham, AL


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1) Develop "Modular Key Plan“

2) Building Will be Divided Into Modules

3) Maximize Size of Modules

4) Avoid Shipping “Air”

5) Minimize Total # Pieces Fabricated, Transported & Installed

6) Typical Sizes - 12'-15' Wide, 50'-60' Long & 11.5'-13' High

7) "Modular Key Plan” Determines Bearing Points, Hoisting

Lugs, Loads & Foundation Design, Etc.

Modular Key Plan – Again Early in Process


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1) Connections to On-Site Elements & Module-to-Module

2) Connections to Foundations, Structural Elements,

Elevators & Stair Cores

3) Evaluation of Prefab Components :

• Thermal Performance

• Acoustics

• Water Intrusion (During Construction)

• Fire/Smoke Penetration

• Exterior Façade Interface

Prefab Connections/Demarc’s

Corridor MEP Rack Installed & Ready for Rated Wall to be Installed Beneath & Ready for Connections to Traditional Jobsite Installed MEP Components


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Procure Modular Manufacturer Services

1) Joint Effort

a) Owner Issues P.O. FOB Jobsite, Assigns Install to CM

b) CM Has Skin in Game

c) CM Installs With Local Forces (Possibly XBE)

d) Supervision/Training by Vendor

2) All CM Effort

a) CM Issues P.O. FOB Jobsiteb) Installs With Local Forces as Depicted Abovec) Probably the Preferred Method

3) Don’t Let Contract Tie Your Hands

Engage Modular Manufacturer


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1) Establish Coordination During Design

2) Spec Section 13 Prefab Modular Bathrooms

3) Develop a Detailed Responsibility Matrix

(See Example This Page)

4) Matrix to be Included in RFP

RFP Scope of Work Coordination

BATHROOM PODSResponsibility Matrix


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Project Delivery Method

1) Traditional Design/Bid/Build Model Not Well Suited to Prefab

2) Need Collaborative & Iterative Delivery Method (CHI Baylor)

3) Like Design Assist, Design/Build & IPD (Integrated Project Delivery)

4) Engagement EARLY in Design Process

5) Early & Real Costing By Having MM Onboard Early

6) MM Able to Provide Guidance & Coordination More Effectively

1) Regardless of Delivery Method, Early Involvement of Modular

Manufacturer is Crucial

Prefabricated MEP Corridor Racks Installation Mount Carmel Hospital- Columbus, OH


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1) AIA Document – Defines Responsibilities

2) Detailed Scope of Work Checklist (See Example at Right)

3) Communicates Tolerance & Interface Details For

Connections On-Site

Prefab Design Coordination Check List


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1) Small But Critical Component in Process 2) High Degree of Confidence in Field Layout (Tremble, Etc.)3) Goal - Increase Shop Hours & Minimize Field Hours4) Precise Information to Shop Personnel (Spool Drawings,

Labels. Etc.)

5) Robust Virtual & Field Trade Coordination is Mandatory

BIM (Leveraging Technology)

Prefabricated Bathroom Pod at UTSW Dallas


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Maintaining Compliance

1) Determine Local Permitting Requirements EARLY

2) Must Meet Local Codes Regardless of Manufacturing Location

3) Most States Have Specific Modular Building Program, Some Don’t – Indiana Does

4) State Building Program – 1) Approval of Modular Manufacturer, 2) QA/QC, 3) Plans

5) Inspections Will Be Req’d Both at Shop & On-Site When Connecting

6) State-Licensed Third-Party Design Agency Conducts Off Site Inspections

7) Labels (Bar Code Travelers) Signifying Code Compliance

Mount Carmel AHJ’s, User Groups, A/E,

Facilities, Program Mgr. InspectingMEP Corridor Mock-Up’s


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Prefabricated MEP Corridor Racks Flown Into Mount Carmel Hospital-Columbus, OH

1) Finance - Cash Flow Heavier at Front End vs. Traditional

2) Insurance - Transportation, Increased Use of Cranes

3) Insurance - Significant Labor Off Site Can Influence

And/Or Negate OCIP’s & CCIP’s

4) Insurance - Builders Risk For Warehouse Storage

5) Insurance - Workers Compensation Special

Classifications (Off Site Less Expensive)

Legality, Financing & Insurance


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1) A/E’s Establish a "Design Freeze"

2) “Modular Key Plan” is Now Done

3) Loose Place in Line at Fab Shop

4) Cause Re-Tooling, Re-Ordering & Re-Mobilizing

5) Late Changes:

• Costly

• Severely Affect Production

• Adversely Impact Schedule

6) Deliver Prefab Ahead of Envelope

Design Freeze


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1) Watch Dog Required to Monitor2) Coordinate Parallel Process of Off-Site Manufacturing Against On-Site

Construction, Stay in Sync!3) Select Finish Materials & Fixtures (Much Earlier Than Typical)

4) Mock-Up’s Early Approval

5) Longer Lead Time Materials Ordered in Advance

6) Maximize Use of JIT (Just-In-Time) Delivery

Manufacturing/Monitoring Site Progress

Prefab Utility Bridge - Good Samaritan Hospital, Vincennes, IN


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Transportation, Staging & Assembly

1) Expect The Unexpected - Transportation Glitches (DOT Intervention,

Vehicle Breakdowns, Driver Emergencies)

2) Back Up Staging Area/Warehouse Standing Ready

3) Relief Valve to Capture Overflow Deliveries - @#$%&! Happens

4) Frequent Adjustment of Delivery Timetables

5) Site Staging Ready For Hoisting (or)

6) Pick Directly From Back of Truck (Ideally)

7) Place Module, Secure to Structure, Install Envelope

8) Mitigate “Unplanned Events”9) Life is Like a Box of Chocolates… Unplanned Events Will Occur

Example of “Unplanned Event”


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WHO


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Engaging Modular Manufacturer (Cont.)

Selection of Modular Manufacturer:

1) Team to Research The Industry Leaders

2) Request Referrals

3) Review Case Studies

4) Accreditations, Certifications

5) Memberships With Professional Associations

6) Issue Pre-Qualification Questionnaires

7) Create Shortlist

8) Pull The Trigger

Healthcare Modular Opportunities


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WHERE


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• Where Does the Off-Site Manufacturing Take Place?

• Solution #1 - Prefabricated Offsite Construction (POC)

• Solution #2 – Prefabricated Modular Manufacturing (PMM)

Two Primary Prefab Solutions

No Way!

Two?


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Solution #1 - Prefabricated Offsite Construction (POC)

1) Local in Nearby Leased (Typically) Warehouse, Single Project

2) Establishing Processes For The First time

3) Temporary Fab Shop, Break Down Later

4) Traditional, Local Labor Sources/Methodology (Equals More $)

5) Coordination of Multiple Trades (First Time Establishing Flow of

Materials & Labor, Tooling Up)

6) Requires Significant AHJ Oversight


16’ Wide Corridor MEP Racks Built in Nearby Warehouse for Mount Carmel Hospital Project in Columbus, OH

POC


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Solution #2 – Prefabricated Modular Manufacturing (PMM)

1) Manufacturing Plant or Factory (Likely Remote = less $)

2) Transportation Costs (Likely Equals More $)

3) Continuously Manufacture Product For Multiple Projects

4) Repeated & Refined Process (Permanent Assembly Line

Approach)

5) Non-Union Most Likely

6) Licensed & Certified, Minimal AHJ Oversight (3rd Party)


BLOX Assembly Plant Birmingham, AL

PMM


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1) Cultural Shift in The Industry as a Whole

2) Only 33% Surveyed Owners Utilize Modular on Capital Projects

3) Owners General Lack of Experience (Fear of the Unknown)

4) Limited Supply Chain of Experienced Modular Manufacturers (But Growing Rapidly)

5) Confusion About Building Code - Applications/Approvals Process

6) Local Labor Union Acceptance (Project Labor Agreements – PLA)

7) Funding Models - Higher Upfront Costs/Different Cash Conversion Cycle (Cash Flow)

8) Getting Designers to Change Their Processes

9) Project Delivery Method Preventing Effective Prefabrication Planning

Hurdles to Growth – Past & Present



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Evolution of Modular Practices

1) MBI (Modular Building Institute) Predicts Significant Shift Towards

Modular & Other Off-Site Approaches

2) Shortage of Skilled Labor Exacerbated by Large Numbers of Workers

Retiring

3) Other Industries Have Become Heavily Reliant on Industrial &

Automated Processes

4) Inevitable That The Building Industry Will Follow Suit

5) G.C.'s & C.M.'s Starting Modular Construction Divisions

(DPR/SurePods & Digital Building Components), Cannon

Design/Modular Design +)


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Evolution of Modular Practices

Improved Team Approach

1) Replacing The Silos That Traditionally Existed in the Design &

Construction Fields

2) Adopting More Integrated & Interdisciplinary Modes of Operating

3) Teamwork - Seeing More Use of Design-Assist, Design Build & IPD

(Integrated Project Delivery)

4) Changing Circumstances – Time to be a Change Agent of Industry

Processes


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Q&A

Documents

Modular Practices & Prefabrication: Yesterday, Today