2

Bespoke modular (off-site) construction by design

Table of contents

P3 Introduction
P3 Traditional volumetric modular
P3 Bespoke modular design
P5 The drivers for bespoke modular construction
P5 Constraints to modularisation
P6 Advantages
P7 Disadvantages
P8 Case study: Heathrow AirLinks
P9 Conclusion
P10 Contact details
P10 Notes to Editors







Front cover images:
(Left to right, top) Farringdon train station roof lights; Heathrow Airport walkway airlinks; Farringdon train station shed roof;
(Left to right, bottom) Reading station platform canopies; The Moors modular cladding (Sheffield); Farringdon train station shed roof.









3
Bespoke modular (off-site) construction by design


Introduction
This white paper highlights the growing trend towards bespoke (off-site) construction, a
process where a structure is constructed off-site, under controlled factory conditions,
before being transported to site and subsequently installed. Two types of modularised
structures are identified; off-the-shelf units and bespoke, or re-engineered solutions
prevalent across the aviation, rail and residential sectors. The white paper also
discusses the distinct advantages of modular construction versus traditional methods,
namely reduced time on site, increased health and safety standards, as well as higher
levels of quality control.
Traditional volumetric modular

A traditional view of volumetric modular units is generally of the Portakabin or Terrapin
type off-the-shelf building products. Alternatively, for specific unitised design, it is
typically hotel bedroom pods, toilet pods and prison units which contain sufficient
repetition to make the setup of efficient production line techniques worthwhile and
economic.

The selling message supporting these products is generally to buy an off-the-shelf
product with minimal variation, using a specific unitised design with many identical units
in order to make manufacturing costs viable.

Bespoke modular design

Bourne Construction Engineerings view of bespoke modular is to take a traditional
design solution (which may already be designed up to RIBA design stage F) and remodel
the structure to produce an alternative off-site, fully integrated solution. The re-
engineered solution must be able to deliver the original design intent, whilst overcoming
the particular site (or client) constraints, and be constructed and commissioned on site in
as short a space of time as possible. The optimum solution is to achieve a plug and
play performance, where the installation time is minimal and the product is fully
operational at handover, with a single on-site operation.

The objective is to deliver a product to site complete with structure, envelope claddings,
roofs, glazing, doors, floors, heating systems, electrics and air conditioning - all designed,

4
Bespoke modular (off-site) construction by design


delivered and installed as a modular unit. In other words, its a product delivered in a
condition which is as close as possible to a completed structure. One such example are
the AirLinks being installed at Heathrow airport throughout 2013, which is highlighted as
a case study later. The key to success, as with so many other construction activities, lies
in the details at the material interfaces.

The plug and play philosophy needs to be considered at all major junctions of modular
unit material and systems. Standardisation ensures all features of the original F stage
design are retained. Re-engineering only occurs when absolutely necessary, without
changing either the structural performance or the functional intent of the building form.

It is important to note there is usually no constraint to the minimum number of units
applicable to this form of bespoke modular construction, which has been widely adopted
at airports, across the rail industry, process industries and confined inner city
construction sites.
Images of bespoke modular installation (clockwise from top left):
Reading train station platform canopies; Heathrow process works, Heathrow airlinks, Farringdon train station roof lights; Farringdon
train station shed roof; Heathrow airport toilets.





5
Bespoke modular (off-site) construction by design


The drivers for bespoke modular construction

Steelwork is the ideal framing material for producing relatively lightweight modular
construction. The primary driver for any bespoke modular project is usually generated by
an existing continuous activity which is too expensive, or where it isnt viable to have a
prolonged shut down period. One such example is the current works at Reading train
station, where 450 individual modular canopies are currently being fitted not just to the
existing station platforms but also over five new platforms being constructed. The
bespoke off-site project is part of the wider redevelopment of Reading station; the
canopies are currently being constructed in a factory environment in Poole, Dorset,
before being transported and installed at the station. This method was chosen over
traditional processes given the works are being carried out alongside and over one of the
busiest rail lines in the country, where disruption to the 45,000 passengers who use the
station on a daily basis had to be kept to a minimum.
Reading station canopies during construction in Bourne Construction Engineerings factory; canopies being prepared for
transportation; canopies being installed at Reading train station.

Informed clients are generally instrumental in bringing pressure to bear on design teams
to produce modular solutions of this type. The viability of the design process requires an
overriding need for the least possible duration and disruption to the existing site
operations. There is also a need to place wide scoping packages with a single supplier,
to reduce the overall construction risk profile.

Constraints to modularisation
Size is the first consideration, with the two driving forces being the physical dimensional
size and/or unit weight. These constraints are influenced by the manufacturing facility
and then the ability to transport the module to a site or assembly area.


6
Bespoke modular (off-site) construction by design


Modularisation demands higher tolerances than traditional build at the material
interfaces, which must be addressed in any re-engineering exercise.

There is a necessity to understand the advantages and limitations of the off-site
manufacturing processes and techniques, which are then coupled with the ability to
adopt a flexible approach to design modifications, to accommodate the new form of
construction. Truly collaborative design team working (with the manufacturing designers
at the heart of the process) is a prerequisite.

Advantages

Modular construction boosts a number of distinct advantages:

Improved off-site quality controls with the ability to prototype or verify initial module
design quality.
Speed of construction; at Reading station for example, the amount of man hours on
site has been reduced by 80%. Stair-in-a-day technology has also been designed,
thanks to off-site innovation:
CGI of the BourneStair; BourneStair installed at Pinewood Studios



7
Bespoke modular (off-site) construction by design


Difficult access conditions can be overcome.
Single source procurement from the supply chain.
Modularisation is a perfect environment for the adoption of BIM (Building Information
Modelling) bringing multi-materials and systems into a single virtual modelling
package.
Integrated material and service design solutions are possible.
Minimal site setup and attendance is required to complete construction.
Safety risks on site are dramatically reduced. This was evident at Farringdon station,
where modular roof lights were installed over a modular train shed roof. The off-site
approach resulted in Bourne Construction Engineering being award the Network Rail
365 Award for a consecutive year on site with no reportable accidents.
Construct to commissioning time periods are short compared to traditional
construction standards.
The off-site environment also allows the client to see their work prior to installation,
often making use of prototyping.
Modular cladding (Sheffield); modular construction in a factory setting (Reading station canopies); example of a modular balcony

Disadvantages

Early design commitment to the modular design process is required.
The off-site programme is required to include the factory construction period for all
materials, systems and services.
Project craneage requirements are often significantly larger than traditional build.
The costs model is very different to the equivalent on-site construction process and
must be fully taken into account when considering the value of an integrated, off-site
product.


8
Bespoke modular (off-site) construction by design


Case study: Heathrow airport

One current example of bespoke modular design can be seen at Heathrow airport, where
a number of AirLinks (architectural, fixed link walkways) are being installed at the new
T2. Once installed, the off-site constructed structures will transport passengers from the
terminal building directly to the aircraft.

Heathrows new AirLinks have been constructed off-site, in a factory environment (Poole,
Dorset). Each unit includes full acoustic and thermal installation to ensure a controlled
internal environment. A unique connector frame allows separate modules to be
connected and sealed together; the connector frame also allows for simple interfacing
with the host building (airport terminal).
AirLinks diagram including labelled features

The bespoke engineering includes a robust steel structure crafted to directly receive
composite cladding, roofing and glazing. AirLinks is also a fine example of lean
construction; the modular build contains no secondary steelwork or flashings.

As previously discussed, true off-site, modular structures achieve plug and play
performances and AirLinks are no exception to this rule. The units are installed the same
day as delivery and their robustness makes them suitable for global transportation.
Throughout 2013, a total of nine AirLinks will be delivered and installed at Heathrow T2.


9
Bespoke modular (off-site) construction by design


Conclusion

Bespoke modular (off-site) construction is not necessarily suitable for all projects, but for
those projects where the appropriate drivers exist, it can provide huge advantages for the
successful completion of a construction project, with minimal disruption to the existing
processes.

All of these types of project require an element of integrated re-engineering to enable
modularisation to take place, and the manufacturing designers need to be at the heart of
this re-engineering process. A truly collaborative team of manufacturers, constructors,
materials and systems designers are required for the project off-site detailed design and
planning stages.

Transportation and lifting methods have to be properly engineered to ensure the quality
of the end product is maintained.

Modules can be constructed to the highest quality and tolerance, both in the relative
safety of factory conditions, significantly increasing access and safety at the work front.

The project cost model should be reconsidered as a holistic item for the overall
construction, taking into account the reduction in site activity and the delivery and
commissioning of an integrated off-site, plug and play product. Building costs are
distributed across the project in a different way, with a higher percentage being spent on
the off-site process. The big gains will usually be realised from the savings due to
minimising disruption of facility services.















10
Bespoke modular (off-site) construction by design




For further information, please contact:

Lauren Wallace, Publicity and Communications Manager, Bourne Construction Engineering
Tel: 01202 746666 / 07792 246326
Email: lauren.wallace@bournegroup.eu


Follow us




Notes to Editors:

1. Bourne Construction Engineering is a leading steel specialist, advising on the design,
production and construction of structural steelwork. Founded over sixty years ago,
Bourne Construction Engineering consists of six divisions: Bourne Steel, Bourne Special
Projects, Bourne London, Bourne Engineering, Bourne Parking and Bourne Off-Site
Solutions.

2. Bourne Construction Engineering operates across all sectors but specialises in rail, power
& energy, airports, car parks, education and refurbishment.

3. Bourne Construction Engineering is an award-winning business; in 2012, the company
won the Construction News Steel Specialist Award and received an accreditation from the
Structural Steel Design Awards.

4. Bourne Construction Engineering employs more than 150 highly-qualified staff, based
onsite and across four regional offices.