modulor overview pod vs traditional

Strategy team

Modulor business overview

7th February 2012

CONTENTS

Introduction About MODULOR Transition: In–situ to Pod Cost comparisons: In-situ vs Pod The process from concept to mock up The site implications, challenges and advantages Factory Tour

Modulor Modulor is the offsite manufacturing

arm of the Laing O’Rourke group based in Dubai UAE. The business has a track record of delivering pre engineered modules across the UAE stretching back to 2005 with the first “bathroom pods” being manufactured and installed into the Atlantis hotel.

Employing modern methods of manufacture the modularisation techniques divide complex elements into manageable units which promote ‘right first time’ installation, leading to more predictable budgets and time planning, as well as ensuring a safer, cleaner and more productive site.

Based in Jebel Ali, the factory has a capacity of around 150 units per week and offers its clients a “one stop shop” and has become the manufacturer of choice for numerous prestigious projects across the UAE and GCC.

Transition: In-Situ to Pod

Transition: In-Situ to Pod

Early intervention in the process Commitment of the Main Contractor/Client Early involvement of MEP contractor Openness on budget and clarity for final finishes Mock up for both pod and riser connectivity Value engineering built in from day one Structure and design intent for fire and sound Site logistics and pod routes

COST COMPARISON

IN-SITU

PODVS

COST COMPARISON

POD Vs TRADITIONAL BATHROOM

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

BASE WATERPROOFING WALLS TEMPORARYDOORS

SURFACE FINISHES SANITARY ITEMS SPECIAL PURPOSEFIXTURES

MEP SERVICES TESTING &PROTECTION

INSTALLATION

BUILD COMPONENT

CO

ST (A

ED)

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

CUM

ULAT

IVE

COST

(AED

)

POD

TRADITIONAL BATHROOM

TOTAL POD COST

TOTAL TRADITIONAL BATHROOMCOST

24% Cost difference

PROCESS FROM CONCEPT TO MOCK-UP

The Production Process

Pre cast base slab with integrated drainage

Setting out and line and leveling the base

Frame assembly LGS

Composite materials

Pre cut and preparation

Offline assembly

MEP first fix and test

A view inside the finished pod

Final PDI and QA sign off

THE SITE IMPLICATIONS, CHALLENGES AND ADVANTAGES

Site Implications / Challenges


Internal Platform For Disabled Pod Only


Understanding the interfaces with the building and structural design

BIM modeling and 3D overlays The MEP coordination and interface with the pod Logistics and product handling The pod route Delivery and sequence planning

PROJECT OVERVIEWAL ZEINA, AL RAHA BEACH DEVELOPMENTABU DHABI

Al Zeina project is a 1221 dwelling residential project in Abu Dhabi UAE; the overall project value is approximately 550 Million GBP. The project team submitted a report to the client (ALDAR Properties) to demonstrate the benefits of using bathroom pods (5,024 No) as opposed to the traditional in situ bathrooms. The report illustrated the benefits that would be achieved on Cost, Quality and Programme. ALDAR approved the proposal and the following are the quantified benefits derived from this decision.

Built up area: 730,000m² Client: Aldar PropertiesValue: AED 3.3 Billion (£)589MSize of Site: 133,000m²No. of Residences: 1221No. of Precincts: 8No. of Pods: 5024

AL Zeina – Project Statistics

Cost Saving 13 %. Pods client programme 48 weeks, In situ bathroom

programme 68 weeks (20 weeks saving on the bathrooms programme).

Actual delivery programme 40 weeks (actual saving total 28 weeks on the bathrooms programme).

Total labour on site 150 at peak as opposed to 1,062 for the in situ bathroom option.

Factory assured quality, saving on the overall snagging time for the full project has been projected at over 450,000 man hours (3 men for 3 days (30 hours) x 5024 bathrooms.

Customer Feedback

Tim KellyProject Leader, Aldar Laing O’Rourke

“To be able to complete over 5000 modular bathrooms in 10 months and to an extremely high standard of finish, using a minimum of on site resource is unprecedented and provided the project with a massive advantage and is testament to the dedication of Dave and his Modulor team.

I feel that the quality of the product is superior and this view is shared throughout the Consultant and Development teams. This result would not have been achieved with in-situ based solutions.”

LIST OF COMPLETED AND CURRENT PROJECTS

Advantages over traditional In-Situ Construction

Shorter and predictable build time with cost certainty upfront. Room completion taken off construction critical path. Factory controlled consistent quality built into the process and

product. Factory testing promotes consistent interface with site MEP

operations & reduces commissioning time. Vehicle movements reduced by up to 90% (typical). Improved Health & Safety performance. Sustainability and waste reduction 1.5% Vs 7% on site.

FACTORY TOUR

modulor overview pod vs traditional

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