Off-Site Wood Construction:

What, Why, How and the Future.

Randall S. Walter, AIA, LEED AP

Disclaimer: This presentation was developed by a third party and is not funded by WoodWorks or the Softwood Lumber Board.

“The Wood Products Council” is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES), Provider #G516.

Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. Certificates of Completion for both AIA members and non-AIA members are available upon request.

This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of han-dling, using, distributing, or dealing in any material or product._____________________________Questions related to specific materials, methods, and services will be ad-dressed at the conclusion of this presentation.

Course Description

Due to skilled labor shortages, compressed schedules, and the potential for greater quality control, off-site wood construction has become increasingly popular. This presentation will cover the unique design and construction techniques associated with pre-fabricated and off-site panelized wood systems. An introduction to the different levels of off-site construction and review of associated products and services will be followed by a demonstration of cost and schedule benefits based on real-world projects. A step-by-step process will be presented for designers new to off-site construction, with information on how to find and utilize partners and resources, the integrated design process, and differences compared to traditional on-site methods. Trends and future projections for the use of off-site construction, as well as its advantages, will also be reviewed.

Discuss factors such as skilled labor shortages and potential for greater quality control that have prompted the increased use of off-site wood construction.

Learning Objectives

Using commercial and multi-family case studies, review the cost and schedule savings realized through the use of off-site wood construction.

Highlight design and construction techniques unique to off-site construction such as assembly selection, sequencing and parallel construction.

Demonstrate the tools available to design and construction professionals looking to implement off-site construction, such as design resources, partners and industry associations, and 3D modeling methods.

Credit(s) Earned

Credit(s) earned on completion of this course will be reported to AIA CES for AIA members. certificates of Completion for both AIA members and non-AIA members are available upon re-quest.

This course is registered with AIA CES for continuing professional education. As such, it does not include content that may be deemed or constructed to be an ap-proval or endorsement by the AIA of any material of con-struction or any method or manner of handling, using, dis-tributing, or dealing in any material or product.

Questions related to specfic materials, methods, and services will be addressed at the conclusion of this presentation.

Big breakthroughs happen when what is suddenly possible meets what is desperately necessary.

-Thomas Friedman

An Industry Unaffected by Other Technology

1820 1940 2006

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A Challanged History Built-in inefficiency

• Weather-based delays, shutdowns• Linear Process• Raw materials to finished product under difficult conditions,

with inadequate tools

Skill degradation• Extreme personnel turnover rates (20%-60%)• Majority of workers have minimal education• Lack of education, skills & attitude for new demands• Minimal or zero requirements

Poor quality• Most defective products consumers purchase..• 15% - 80% serious defect rate• Decades long industry culture of accepted compromise

• 80 miles an hour• Fuel efficient engine• 200,000 + miles w/ little maintenance• Battery powered electrical system• Multiple computers & sensors• Auto Heating & Cooling• Complete sound system• Comfortable Seats w/ power controls• Airbag protection• Defects unacceptable

For $20,000

• Just sits there• Walls & Roof• Lights & outlets• Defects accepted

For $20,000

Precise• 1/32” tolerances (thickness of a business card)

Consistent Quality • Industrial manufacturing process instead of in-situ (on site)• Equivalent of ISO9001 type assurance

Lean Manufacturing• Ideal work space• Repetition

Develop Sub Assemblies• Added value through integration• Packaging waste control

Continuous Improvement• Interface Control • Feed Back Loop

Off-Site Opportunity

Prefab Architecture by Ryan Smith http://itac.utah.edu

Refabricating Architectureby Steven Kieran and James Timberlake

Other Reading

Other Industries Get It

Would You Build a Car in Your Driveway?

Off site/prefab opportunity: area of expansion

Modular: reasonably well defined industryConstrained design

Value Proposition

On-Site• Easily disrupted by weather • Challanging safety environment• Handling challanges• Theft

Off-Site• Compressed schedule• Lean manfacturing• Waste control• Better jobs

Intersection of Strategies

Design | Build | DeliverDigital Fabrication Offsite

Prefab – Kits, panelization, modulesMontage – site for assemblyReduced site impact – time, waste

= 3D printed buildings

Virtual Building

Precision TEAM

BIM

CNC IPD

Built From Model: Parrallel Processing

Foundation

Fabricate InstallModeling

Mech Connections

Exterior Finishes

Layout from plans, cut, attach, measure, order, wait, install, measure, cut, fit,

Shell

Site Construction

InstallMillwork & Products Modeling Fabricate

Open-Built & Montage

Principles and Innovationsfor

21st Century Homebuilding

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Learn from Everywhere

Montage

New EnglandTF Legacy Building

Off-site benefits and skills3D modeling value

Discipline of connectionsSite efficiency tools & logistics

Discipline & Skills

JapanLean Manufacturing

KaizenPrecision

Power of ModularityTradition of Perfection

FrancePride in Craft/training

Craft knowledgePersonal discipline

HumilityHistorical Perspective

Holland Open Building

Lives must PrevailRational Design & Building

Time based organization Sustainability through Adaptability

Dimensional Coordination

ScandinaviaOptimization

Most Off-Site Construction Appropriate TechnologyBest Energy Standard

Building ScienceMontage Design

Germany/Austria/SwitzerlandCNC Tools

Software LeadTechnology AdaptationModern Manufacturing

Advanced Education for tradesDurable Building standard

Montage Design & Building

“Montage is about prefabrication and assembly...the dual nature is identified by the dichotomy be-tween montage as a construction strategy and montage as a aesthetic strategy.

...a way of thinking about architecture as an instru-ment rather than a monument..” - Charlotte Bundgaard, Montage Revisted

Montage - Any combination of disparate elements that forms or is felt to form a unified whole.

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Montage Building

Site is the worst place to attempt to control • Quality• Efficiency• Cost• Time• Job satisfaction

Site for assembly only; avoid cutting and shaping.

Open-Built Strategy 50,000 to 50 (Distilling Parts and Pieces into high value Building Elements)

Building Element FabricationA continuum of change

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Everything Modeled:

Power of BIM• Design = Simulated building• Automated PM information—costs, supply chain,

shipping, etc.• Automated cutting and shaping machine code

Plan, Deliver and LEAD

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BIM to CNCOur Tireless Workers

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Gantry System: Wall Production

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Flat Pack Virtual and Actual ShippingRecycled Wrapping

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Site Montage

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Site Assembly

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Mechanical Cartridges

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Cartridge Installation

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Core-WallIntegrated Mechanical System Element

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Core-Wall Installation

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Bath and Mechanical Room Pod

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Mechanical Room Module

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Bathroom Pods Montage

Open Building Innovation

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How Buildings Learnby Stewart Brand

Supportsby John Habraken

Additional Strategies: Open Building

Shell Impact: Public control, regulationIntent: Long term durability, sustainability Players: Architects, Engineers, Public Agencies

Infill Impact: Private, freedom Intent: Easy change, modificationPlayers: Inhabitants, interior designers, semi-professionals.

Disentangle the Process

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Montage Building Recipe:21st Century Skills, Old World Craft Attitude

Operating System

• 3D software automation• OBGrid: Montage Design• CNC cutting and shaping• Open-Built disentanglement

Lean Manufacturing

• Constant improvement• Custom production• Mass Customization

High skills/craftsmanship

• Discipline, Pride• Service to society

Building Science

• High performance• Net Zero

Project Examples: South Face Village

Project Examples: Coastal Maine Botanical Gardens

The “Hole” Story

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Even Renovation

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Small Modules, Combined Modules

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A Better Way to Build

• Build time will be 20 days vs 100 – 260 days• Off-Site Impact: 75% vs 10% to 30%• Safe working conditions• Consistent working conditions• Good Jobs:

• Discipline, Training, Skills• Empowerment; low turnover

Montage = Combination of Disparate Elements that Forms or is Felt to Form a Whole, Unified, Singular Image

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How to get Started

Need site space• Deliveries• Boom truck or crane• Evaluate Access

Partners• Build a Team• Decide where

info will live.

Different flow to decisions making and commitments• Get Everything in Model Early• Work the Model • Rely on Model

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Important Differences

On-Site• Schedule allows for field changes• Each step adjusts to previous dimension

and (in)accuracy

Off-Site• Less Design Flexibility• Accuracy is paramount - site portion affect install fit• Cost may or may not be higher, however time=$• Anticipate need to protect installed finish materials• Design the schedule and share extensively

Questions?This concludes the American Institute of Architects

Continuing Education Systems Course

Randall S. Walter, AIA LEED APrandall@bensonwood.com