1. “My vision for 2020 is one where
construction methods will minimise
on-site labour – more prefabrication.
Buildings may be more transportable,
moving or growing as required.
Sustainability and re-use of building
materials will drive materials and
construction methods.”
[Quote taken from Hampson & Brandon’s
2004 Report by the Cooperative Research Centre for Construction Innovation, Australia]
4. Prefabrication
Overview Lessons and Strategies Future Opportunities
This brochure 2 Transformations: Looking Forward 8 Digital Design: Parametrics 14
Background 3 International Trends 9 Digital Design: Digital Fabrication 15
Why Prefabrication 4 Prefab World 10 Mass Customisation: Choice 16
Terminology 5 Different Approaches 11 Case Study 1: 3D modular 17
Relocatables today 6 A Systems Approach 12 Case Study 2: 2D kit of parts 19
Relocatables tomorrow 7 Logisitcs 13 Futher Reading 21
Prefabrication | Future Proofing Schools 1

2. Marymede P-12 School, Artwork on a relocatable at
Wiluna Remote Community School by TAG Architects Pepper Green Farm Training Centre, Bendigo
South Morang Currambine Primary School,
by Eco Villages Worlwide
WA
Stairs of a double storey
relocatable by AUSCO
This Brochure> This brochure is about prefabrication. Social, economic and environmental
factors suggest an urgent need to
It is an exciting time to embrace these
‘tipping points’ and explore the interface
It presents ideas and themes that can consider new ways to build. These factors between design and manufacture and
help redefine the way we design and include: engage architects in that process.
construct buildings.
“If I had asked people • shortages of skilled trade labour in Although the focus of our research is the
21st century design technologies present many communities; relocatable classroom, prefabrication
what they wanted, they us with endless possibilities to ‘rethink’ • need for increased construction has the potential to have a much wider
how we design and manufacture and: quality and lower costs; impact on the design and construction of
would have said faster • create a shift from mass-production • need to improve construction schools - and beyond - as we seek more
horses!” to mass-customisation; productivity; efficient, sustainable, quality-driven and
[Henry Ford discussing the mass production of • embrace parametric modelling for economical ways of creating our built
• need for more sustainable, cradle to environment.
the automobile] site specific, value driven responses; cradle solutions;
• maximise the interface of these • increased acceptance of quality It is time to continue prefabrication’s
technologies with manufacturing. prefabrication. ‘design-led transformation’.
Werkhaus @ Bauzentrum
Munich, Germany
Millmont Elementary School, Pennsylvania Student Housing, Spacebox ® by CoCon BV, A variety of styles and approaches
by NRB Inc, Ephrata TU Delft Campus, The Netherlands @ Terrapin-Ltd UK
2 Future Proofing Schools | Prefabrication

3. Digital model based on the 1933 Schindler Shelter System
by David Lister, University of Melbourne
The social and
historical context
Prefabrication has long played a
major and positive role in design and
construction innovation, addressing
social challenges, urgency, and economic
drivers, particularly in the housing market.
Although prefabrication is perhaps
architecture’s oldest new idea [Harker
2007] , it has gone through alternating
cycles of being ‘the next best thing’ or
Background> being shunned. A prefabrication timeline...
“Sadly, much of the There are a number of reasons for this: 1500’s Nonsuch House was built in Holland of timber and assembled in London, fixed with
• For many decades, prefabrication wooden pegs. It was painted to give the appearance of brick and stone.
negative stigma has been used for utilitarian, low cost 1624 + Simple prefabricated houses were transported by ship to new settlements in British
associated with projects or products; Colonies [Kelly 1951].
prefabrication stems • Historical association with cheap 1851 Prefabrication meant that the Crystal Palace was completed in less than six months. The
catalogue housing solutions in Crystal Palace was then dismantled and relocated elsewhere [Kelly 1951].
from the building Australia, the USA and UK;
1914 + Prefabrication helped address British and German housing shortages in the post war era.
category that’s central • A long association with poor quality
relocatable classrooms in Australia, 1916 + Nissen Huts [WWI] and Quonset Huts [WWII] provided a relocatable housing solution for
to our research - the the USA and UK; the army. The Nissen Hut typically took four hours for six men to assemble.
• Manufacturers have led much of the 1933+ Architect RM Schindler created his Panel Post construction system with 9 base
relocatable...” development of prefabrication, with components [Park 2004].
[Future Proofing Schools Research Team]
little architectural input; 1950 + Architect Ernest J Kump Jnr designed prefabricated school systems in California.
• Concerns from architects that 1950 + Prefabrication helped alleviate the skilled trade labour shortfall in post war Europe.
...prefabrication is prefabrication will lead to monotony
and reduction in choice and variety 1990’s With prefabrication, McDonald’s Restaurants reduced build time from months to weeks.
“modern architecture’s [Engstrom et al 2007; Anderson & 1996 Japan’s automated production lines produced high quality houses in record time [Gann
oldest new idea” Anderson 2006]; 1996].
[Harker 2007] • Psychological association of 2002 Arieff + Burkhart’s book Prefab inspired designers and architects.
prefabrication meaning ‘not
permanent’ because of its extensive 2004 CRCCI Report Construction 2020: A vision for Australia’s property and construction
“a long continuum of industry highlighted the important role of off-site manufacture in future construction
use in ‘temporary’ applications;
noble failures” • Tendency for these temporary 2008 Waugh Thistleton’s Stadthaus at Murray Grove, London, was built of cross laminated
[Arieff & Burkhart 2002]
structures to be retained well beyond timber panels which were factory cut by CNC routers then assembled on site to create the
9 storey tower.
their design life;
• Often, relocatable classrooms that 2010 Sekisui House, one of Japan’s high quality prefabricated housing manufacturers,
launched in Australia.
are intended to be ‘temporary’
instead become permanent fixtures 2011 Time for a paradigm shift in Australia’s prefabrication building industry...
of the school.
Prefabrication | Future Proofing Schools 3

4. Baufritz Display Village
Erkheim, Germany
Why prefabrication?> Werkhaus @ Bauzentrum
Munich, Germany
Gruber @ Bauzentrum
Munich, Germany
“Off-site fabrication Time for Change Speed Sustainability
is about reinventing Prefabrication is now on government Site preparation can occur in parallel refer Minimum site disturbance, tightly
agendas in Europe, the United States and to building manufacture on the factory managed material flow and construction
the way we build,
carefully considering
Australia where it’s seen as an important
way of improving quality and cost within a
floor. This saves time, and can also save
money. 2 waste, and pre-planned disassembly can
reduce overall environmental impact of
slow changing construction industry. construction.
how we assemble and Quality
Some notable reports are: Cost
ultimately disassemble • In the UK, the 1998 Egan Report:
It can consistently achieve predetermined
quality in a factory controlled Although there is often a cost premium
our buildings.” Rethinking Construction 9
environment. associated with the transport to site or
[James Timberlake, KieranTimberlake, research • In the USA, Advancing the cranage, these front-end costs should
interview December 2011] Competitiveness and Efficiency of the Safety be balanced against the faster time to
U.S. Construction Industry10 occupation which can: generate income
In a factory environment most of the work
• In Australia, the 2004 Construction can be conducted at waist height. Health earlier; lead to lower site overheads due
2020: A vision for Australia’s and safety is also easier to control in a to less time on site; offer greater cost
property and construction industry11 factory. certainty due to minimal weather delays;
and provide an earlier design freeze due
The convergence of these factors, Skills to requirements of the manufacturing
combined with emerging technologies process.
and the recent resurgence of interest in In communities with a shortage of
prefabrication in the design community, skilled trade labour, the production line Impermanent site
means that prefabrication is more viable can be organised to employ less skilled
and relevant than ever. labour. Some systems can be installed A client may lease rather than own the
or assembled by low-skilled labour under land for a proposed project. Some sites
9 The 1998 Egan Report critiqued the British supervision. may have title or zoning restrictions
construction industry as inefficient, adversarial, that disallow a permanent structure. A
and slow to embrace change prefabricated building can be moved to a
10 This report highlighted a central role for off- new location at a later date.
site manufacture in the future of US construction.
11 The vision included an increase in off-site
manufacture but the authors also noted the
natural conservatism in the local market.
4 Future Proofing Schools | Prefabrication

5. Overview
Within the design and construction industries, prefabrication is a broadly understood
concept, however the large number of terms used to describe it can lead to
misunderstandings and confusion.
Prefabrication is an ‘umbrella term’ and there are a wide range of construction types and
processes that sit under this heading. The following diagram categorises some commonly
used terms that we have come across during our research,highlighting the category of
‘relocatable’ classrooms as just one small sub-set of prefabrication.
There are two main approaches to prefabrication:
• 3D off-site or modular construction: factory finished modules that are joined together
on site. This approach is most commonly used for current relocatable classrooms.
• 2D off-site or kit of parts: factory made | prepared | drilled components that are
Terminology> assembled on site.
“There’s a wide range prefabrication The School Context
of different terms and Across Australia, our States use
off-site manufacturea different words to describe the same
systems, so let’s make industrialised off-site fabrication modern methods of type of moveable classroom structures.
Currently, Australia’s education
sure that we’re all building systemsb off-site construction constructionc departments use the terms as follows:
talking about the same State Term(s) used
things!” VIC relocatables / portables
[Future Proofing Schools Research Team]
3D off-site 2D off-site NSW demountables / portables
QLD relocatables
modular constructiond kit of partse
NT transportables
volumetric non-volumetric
WA transportables / demountables
sectional prefabrication flat pack SA demountables
TAS demountables
ACT transportables
panelised systems In the media, we also hear these
relocatablesf skeletal systems
portables modules classrooms being described as temporary
post + beam systems or prefabricated classrooms, and in
transportables units slab + column systems
demountables sections the United States and the UK we have
a. The preferred ‘umbrella’ term in Australia elements also come across the terms modular
trailers pods sips [structural insulated panels]
b. Term used extensively in Asia
brown boxes classrooms and terrapins4.
c. A UK term covering construction innovation component sub-assemblies
For the purpose of this document we will
to which off-site manufacture is pivotal
use the term relocatable[s] to refer to this
d. The most widely used term for this category category of classrooms.
e. A commomly used term which is well
Relocatable classrooms need to make a full transition from temporary quality towards a permanent quality 4 Terrapin Ltd has been providing prefabricated
understood by designers
school infrastructure to the UK market for more
f. The term used to refer to this category of than 60 years.
classrooms in the context of our research
Prefabrication | Future Proofing Schools 5

6. Overview
refer The Department of Education in each Australian State is responsible for procuring its own relocatables, however even
within the confines on a single State there is a wide range of climatic and contextual variables.
1 Current relocatable classrooms are generally factory manufactured as 3D off-site or modular units that are transported
to a site in sections or modules and installed and joined together on-site, providing significant efficiency, cost and safety
benefits. The speed of installation is an important factor as buildings can be installed during school holidays so that there
is minimal disruption to the school community. The nature of the modular units also means that they can be moved in
the future if required, even if the intention is that they are to be installed as a permanent solution.
Relocatables> In Australia, relocatable classrooms are often named after the number of modular units that make up the whole building,
for example a Mod 5 or a Mod 10 classroom product comprises 5 or 10 modular sections that are joined together on site.
The Status Quo The Mod 5 Classroom product is an example of a typical Australian relocatable classroom.
“Relocatables are A typical Mod 5 Classroom [VIC] A typical WA Mod 2 Classroom [WA]
getting better in terms 3600 3600 3600 3600 3600
of comfort, but they’re Module 1 Module 2 Module 3 Module 4 Module 5 2400 2400 2400 2400
1200
still quite ugly...”
[A parent, Victoria, February 2011]
3600
Module 1
9600
“Recent natural
disasters mean that Module 2
3600
many schools will
have relocatables
1200
2400
for at least 2 years
during re-building
programmes.”
[Department of Education, Queensland]
“We don’t use our
Smartboard any more ...
the floor vibration
means they need to be
re-calibrated on a
daily basis...”
[A teacher, research interview March 2011] A Mod 5 Classroom interior Mod 5 Classrooms at the factory WA relocatable installed at a school
6 Future Proofing Schools | Prefabrication

7. How do we develop future relocatable
infrastrucuture for schools that appropriately
balances: the client brief, end user
aspirations, site constraints, transport
logistics, fabrication strategies, performance
Relocatables> and economy?
And tomorrow?
Common problems Future needs Moving forward
“This new relocatable refer Heat gain and loss: difficult to manage in refer Relocatables of the future will need to Many of the issues with today’s
current ‘generic’ products; respond to: relocatables stem from the challenges
is great as it has
sliding doors that open 2 Indoor environment quality: acoustics
and light levels are often less than ideal;
1 • a range of climate zones;
• a range of architectural vernacular;
faced by a generic, mass produced
product that is required to perform in a
wide variety of contexts.
on to the deck...” Floors: generally low thermal mass, • a wide variety of physical contexts; Yet they are not specifically customised
[A teacher, Victoria, research interview May sometimes undesirable floor movement; • a range of pedagogies and student for any of these contexts, and are
2011]
ages; generally a ‘one size fits all’ response.
Floor level: typically circa 600mm above
ground for connection crawl space; • and address the common problems. The challenge ahead is to explore
“It would be great if How do you:
design ideas that address the complex
Connections and views: generally limited, issues associated with relocatability and
all the walls were pin- both visually and physically; • develop a design idea that responds transferability.
up surfaces, otherwise to a range of parameters and
refer
Placement: often disconnected from contexts?
they just get covered other school buildings, hidden from view;
3
• develop a design idea that is both
in blu-tack.” Toilets: usually not provided due to customisable and economical?
[A teacher, Victoria, research interview April
distance from soil waste connections; • make it easy to add elements that
2011] Extras: no standard range of ‘extras’ that allow buildings to evolve as needs
are also ‘relocatable’; change?
“We can’t use some of Temporary: often look and feel temporary, • deal with the relocation of buildings
yet can become permanent; to new contexts at some point in the
the relocatables for future?
Details: joins between modules and other
younger children as details add to ‘temporary feel’; Other issues to consider are:
it’s quite a walk to • procurement models
Appearance: utilitarian in appearance,
• the role of architects
the toilet block.” generally designed by manufacturers;
[A teacher, NSW, research interview June 2011] • the role of manufacturers
Transport: design is largely defined by
transport logistics rather than end use. • the interface with end users.
Prefabrication | Future Proofing Schools 7

8. Supply|Demand nexus Key challenges Key Opportunties
The current supply|demand nexus • In Australia, a largely low tech The benefits to consumers far outweigh
illustrates that today’s relocatable prefabrication industry needs greater the challenges, so now is the time to start
classrooms are largely defined by designer and client demand prior investigating new procurement models,
manufacturers and facilities managers. to investing in new digital design new construction systems and a new offer
technologies and the associated to the market place.
Adoption of new digital technolgies, training.
and increasing their interface with • Communication between architects
the manufacturing process presents and manufacturers is often limited
exciting opportuntities for re-defining
prefabrication.
during the design stage as a result The following pages
of contractual relationships and
Transformations> These offer the potential to transform competitive bidding requirements. outline some trends and
relocatables, and prefabrication in This commonly leads building opportunities that lie
Looking forward general. designers to adopt conventional
construction approaches. ahead.
“Society needs better Key Stakeholders and their drivers
quality yet less supply demand
expensive solutions to small number of manufacturers in Australia influenced by perception + stigma
limited collaboration between manufacturers + designers future brand/image to link with quality, design, sustainability, value
the built environment. utilitarian origins in Australia = stigma insufficient current demand to create this shift
To achieve the
challenges challenges
necessary advances stigma manufacturers facilities fitness for purpose
volume|demand compliance with standards
in construction, the perceived design limitations manufacturer designed compliance tailored design
whole process needs to resistance to change
lack of visual appeal capital costs $
cost of sustainability
become increasingly opportunities opportunities
change perception minimal customisation life cycle costs $ change perception
interdisciplinary – create innovative products speed + certainty
quality + sustainability relocatable maintenance costs $
engineering, industrial quality + sustainability
lower cost + higher quality lower cost + higher quality
design, architecture, design-led solutions old stigma cost of transport $ customisable solutions
economics, physics, designers modular vs kit of parts sustainability educators
sustainability, problem solving 21st century learning
manufacture...”
mass customisation indoor environment
[Professor Thomas Bock, TU München, research
opportunities
interview November 2010]
sustainability features all stakeholders work together to: reconfigurable|adaptable
overcome negative perception
visual appeal create greater demand indoor|outdoor links
define new products
site integration create high quality, value driven products quality + design
design-led solutions
modular vs kit of parts source of pride
8 Future Proofing Schools | Prefabrication

9. “Prefabrication cannot
transform poor design,
but prefabrication can
be transformed by good
design and considered
details.”
[Professor Alistair Gibb, University of
Loughborough, research interview November
International 2010]
trends> Student Housing Student Housing Student Housing
HDVN + URSEM BV Mecanoo + URSEM BV Mecanoo + URSEM BV
Key Lessons Japan Europe USA
• Importance of a strong, innovative In Japan, prefabrication is synonymous In Sweden, a large percentage of The USA has an active industry body,
industry body with a research and with innovation and quality, particularly families live in high quality, fair priced, The Modular Building Institute, which
development wing; in the housing market. Toyota has been prefabricated houses. In Germany, conducts research and hosts seminar,
• Investment in cutting edge applying their lean manufacturing display villages show houses from conferences and exhibitions. Despite
manufacturing equipment is a principles to their Japanese housing different manufacturers, demonstrating tough economic times, prefabrication’s
significant investment that requires a division since 1976. that there is something for every taste speed and greater cost certainly could
certainty of volume; and every budget, and that sustainable give it a real edge in a difficult economic
Japanese companies such as Sekisui design is vital. climate.
• The housing market plays a vital role Heim work with finite component sets5
in creating demand for prefabrication from which they can offer their clients a European research projects such as Prefabrication in the USA has shared
innovation; controlled degree of customisation while ManuBuild6 seek to harness the potential some of the issues of stigma with the UK
• Lean manufacturing principles building high quality, architect-designed, of digital technologies to streamline and Australia [Arieff & Burkhart 2002].
and systems thinking are critical competitively priced homes in a fraction manufacturing and building construction. However, in the past decade architects
to innovation and development in of the time of conventional site-built From Lapland to Munich there are house have embraced design-led prefabrication.
prefabrication; methods. manufacturers use fully computerised This has led to a ‘renaissance’ although
• Prefabrication has a vital role to play CAD CAM production lines, many working price has kept some of these ‘designer
Most of these companies did not evolve with timber. versions’ out of reach of the masses.
in the future of a more sustainable, from traditional craft based construction
efficient construction industry; firms, but were set up by building material Hotel chains such as Travelodge build
• Architects have an important role to companies to create a showcase for their their hotels using 3D modules, and often
play in the design and development products [Gann 1996]. the fittings and furnishings are already in
of future prefabrication systems; place. Recently, prefabricated student 6 This industry-led, pan-European research
• Architecture Schools in Europe will housing projects in excess of 20 floors project ManuBuild ran from 2005-2009 with 25
increasingly include more teaching have been completed. project partners including the CIRIA, Technical
of industrial design thinking to help University of Munich, Loughborough University
The UK’s industry body Build Off-Site is
bridge the gap between architecture and The University of Salford. Research papers
working hard to redefine prefabrication as
and manufacture. can be accessed at: www.manubuild.org
efficient, sustainable, and quality driven.
5 In 2005, Bock wrote of Sekisui Heim’s It has have a strong research focus. 7 Compiled from research interviews with
prefabricated houses composed from a set of Larger manufacturers are becoming Professor Alistair Gibb, Keith Lyon of Caledonian
some 2 million standard components. increasingly innovative and design-led7 . UK, Stephen Wightman of Modular UK and Adrian
Day of Terrapin Ltd.
Prefabrication | Future Proofing Schools 9

10. Gruber DaVinci Haus
Prefab World>
Bauzentrum Munich
Elk
Baufritz Rubner
“The Bauzentrum near
Munich is a display
village with something
for every taste and
budget... wonderful!
It demonstrates a
range of prefabricated
construction approaches
and style choices
from different
manufacturers...
Rubner Huf Haus The Energy Centre
excellent quality,
energy performance
and value for money
are common to all the
products.”
[Clare Newton on Bauzentrum in Poing near
Munich, Germany, research visit November 2010]
http://www.fertighauswelt.de/musterhaeuser/
ausstellung/muenchen/index.html
10 Future Proofing Schools | Prefabrication

11. 2D off-site 3D off-site
kit of parts modular
non-volumetric volumetric
Different approaches>
flat pack unitised
“The parallel is not Overview 2D off-site approach 3D off-site approach
with building cars on Manufacturers describe a common 2D off-site covers the non-volumetric 3D off-site includes volumetric and
scenario of architects approaching them systems including kit of parts, flat-packs modular systems. There are both positive
a production line; it in same way they would approach a and elemental systems. There are both and negative features:
is with designing and general builder, when seeking a tender positive and negative features:
price on a finalised, bespoke design. For:
planning the production For: • Manufacture concurrent with site
Yet manufacturers are in the business of • Lends itself to mass customisation preparation can significantly reduce
of a new car model.” production: they have their own systems, - a ‘family’ of elements can be on-site time;
[Egan 1998] they need volume and - where possible - a composed in various ways;
level of repetition. • Factory environment not affected by
• Well designed systems can be adverse weather;
So there is a knowledge gap. assembled with low-skilled labour; • Shift work is possible in a factory
Central to the success of prefabrication • Components can be flat-packed to environment;
in any project is adoption of a systems + facilitate transport and delivery; • Modules can be joined to create
manufacturing philosophy, rather than a • Transport logistics and costs can be larger spaces;
conventional construction approach in a less onerous than those of 3D off- • Well suited to projects that can
factory environment. site approaches. readily be ‘unitised’.
We need to embrace a level of product or Against: Against:
industrial design thinking. Prefabrication • Installation not as fast as the 3D off-
needs to be central to the design and • Criticism of ‘transporting air’;
site approach;
construction concept of a project and • Logistical challenge of transport and
considered from the outset for maximum • Shortage of standard, inter-
associated costs.
benefit. changeable products on market.
Requires:
A key opportunity for the future is that Requires:
• Understanding of a manufacturers
of architects, engineers, industrial • Careful consideration of components
systems and parameters;
designers and manufacturers working and their interfaces for effective
together to develop inter-changeable manufacture and ease of assembly; • Understanding of transport
product families for the market place. constraints;
• Building Information Models facilitate
design, assembly and procurement. • Careful design of junctions and joints
between modules.
Prefabrication | Future Proofing Schools 11

12. [adapted from Brand, S. 1994
How Buildings Learn: What Happens After
They’re Built, Viking Press]
scenery
settings
services
skin
A Systems Approach> structure
Old and new ideas site
“The cradle to cradle Lessons from the past The Six ‘S’ Industrial design
approach to design In 1933, the architect R.M. Schindler Designing for prefabrication requires In coming years, the introduction of
of California explored and designed his us to think about buildings and their advanced robotics to the construction
doesn’t currently concept for Schindler Shelters8 which construction differently. industry will require a different design
enter a typical sought to create a new construction
Relocatable classrooms bring their approach from architects. Thinking in
system that not only reduced terms of construction systems, their
building designer’s construction costs but also improved own unique set of parameters into the
equation as building and site are no digital representation and the interface
framework, yet it will building efficiency, speed of fabrication, to fabrication will need to become part of
interchangeability of parts, reduction longer permanently inter-dependent.
the future ‘designer toolkit’.
become increasingly of labour, durability, better design, and If we consider that different elements of
personalised housing designs. a building will have a different life span, These ideas may seem distant however
critical as we meet then we can start to factor this into the in Japan, companies such as Samsung
The beauty of the Schindler’s post and
our obligations to the beam system was that it was based on long term adaptability within the life cycle don’t just make computers and mobile
only 9 components. It was designed of a building or system: phones; they have advanced robotics and
environment through a construction divisions.
so that components were both easy to site eternal
more effective use of assemble on site and easy to replace or In response to this future potential, a
exchange over time. structure 30-300yrs
our resources.” number of post-graduate architectural
[Professor Thomas Bock, TU München, research This is just one of many examples from skin 20 yrs + courses such as those of the Technical
interview November 2010] the past. services 7-15 yrs University München are recognising the
need for greater training in industrial
What could Schindler, Gropius and others scenery - fitout 3-30yrs and product design. Their aim is to
have achieved with access to today’s prepare a future generation of architects
digital technologies? settings - furniture 1yr + for a greater interface with advanced
What could we achieve today and in the Thinking in terms of these layers helps manufacturing technologies and systems.
future if architects and manufacturers us explore issues such as assembly,
were to work together to develop new disassembly and future re-use. We also
systems? need to consider all of these building
layers - inclusive of loose furniture and
8 Park’s 2004 review highlights that Schindler’s fittings - as integral to the design and
system was – quite simply – before its time. procurement of relocatables.
12 Future Proofing Schools | Prefabrication

13. “There are parts of Source: Catholic Education Office, Melbourne
the Northern Territory
which can only be
accessed by barge
for around 7 months
of each year. This
is a real challenge
for us when providing
Logistics> infrastructure!”
Getting to site
[Ian Winch, Department of Education, Northern
Territory, research interview 2010]
Transport Snapshots Strategies
“We need to design
Transportation logistics play a major role RSPB, Rainham Marshes, UK Designers and manufacturers have
with an understanding in selecting or developing an appopriate explored various systems to address the
prefabrication system. This RSPB Observation Platform9 was challenges of transport constraints and
of how buildings will carefully crafted so that installation would rapid site installation, for example:
• Size and weight limitations;
be fabricated and have minimum impact on the sensitive • unfolding buildings, almost origami
• Route restrictions; wetland nature reserve. Haysom Ward
delivered to the site. style, for example those by Prebuilt11
• Availability of lifting equipment; Miller Architects worked with Modular UK in Australia and Blu Homes12 in the
This is a huge shift • Site accessibility. to develop modules that were craned in USA. These facilitate transport and
and installed in a morning, to minimise allow for quick unfolding and site
Optimum freight load dimensions:
in design thinking for people and vehicle movements. installation;
• 3.45m x 12.0m long x 4.0m high are
many architects, but the standard dimensions of a freight Loblolly House,Chesapeake Bay, USA • 3D off-site buildings with hinged
container; verandahs or decks that ‘flip up’
it can result in a new Working in a delicate eco-climate, all during transport;
• The following dimensions are
rigour and purity that inclusive of both load + vehicle: cutting and forming had taken place • hinged cladding that flips up during
in the factory and the house was then transport and flips down upon
is appropriate for the assembled on site. Central to Kieran installation to cover module joins;
general oversize + pilot vehicles
future.” dimensions * + police escorts * Timberlake’s design approach was that
the building would leave virtually no trace • Ming Tang’s conceptual ideas for
[James Timberlake, KieranTimberlake, research
W H L W H L if it were disassembled and recycled – or folding bamboo shelters13;
interview December 2010]
VIC 3.5 4.6 25.0 5.5 5.0 35.0 moved to a new location – in the future.10 • transformable, adaptable, folding
building structures such as those by
NSW 3.5 4.3 25.0 5.5 5.0 35.0
“Today’s relocatables Hoberman14 and Quadror15.
QLD 3.5 4.6 25.0 5.5 5.0 35.0
fit a truck, not a NT 2.5 4.3 19.0 4.5 4.9 30.0 11 www.prebuilt.com.au/
learning experience...” WA 3.5 4.6 25.0 5.5 - 40.0
12 www.bluhomes.com/video/blu-element-
[A teacher, research interview April 2011] 9 http://www.haysomwardmiller.co.uk/page1/ unfolds-in-north-carolina/
SA 2.5 4.3 19.0 5.0 4.9 26.0 page7/page64/page64.html, viewed 30 June 13 www.treehugger.com/files/2008/10/ming-
ACT 3.5 4.6 25.0 2011 tang-folding-houses.php
10 Loblolly House: Elements of a New 14 www.hoberman.com/home.html
TAS 3.5 4.3 25.0 3.9 4.6 28.0
* all dimensions are in metres Architecture 15 www.quadror.com/
Prefabrication | Future Proofing Schools 13

14. Example Client Parameters
space types
headcounts
adaptability over time
value
Parametrically
Prefabrication System Driven Customised
System Outcome
Example Context Parameters
climate zone
orientation
Digital Design> land size
topography
Parametric Design local skills + materials
“Parametrics... a An overview Optimisation
powerful conception Parametric design has been used by Through the use of key parameters of the designers choice, preconceived notions
of architectural design engineers and industrial designers associated with particular typologies can be challenged and rethought and instead,
for decades, for example in the design of innovative and optimal design solutions can be developed. Once values representing
form ...replacing cars, aircraft, and ships. It is a system of individual requirements are assigned to specific variables, personalised instances are
defining key criteria or constraints that we created from a potentially infinite range of possibilities.
stable with variable, want a completed object to respond to.
singularity with Parametric models have a ‘transactional’ quality that allows a sequence of alternative
For many within the architecture decisions to be constructed, exercised, and evaluated. This corresponds to the process of
multiplicity.” profession parametric design has become design at its most fundamental. These qualities translate to an ability to improve workflow
[Kolarevic, 2009] a digital tool for form-finding, leading and be rapidly adaptable to changing input and the inherent precision of information for
to exciting free-form shapes for one-off both performance analysis and fabrication.
designs.
“Architects love From a representation point of view, parametrics allow designers to produce details that
However it is also important to embrace are programmed rather than drawn. The rules of generation are always the same but the
parametric design’s the much broader potential of these results can be different.
potential to create sophisticated professional tools to
produce new and meaningful paradigms;
free-form designs addressing contextual and real-world
issues such as sustainability, quality,
...but mention its constructability and affordability.
potential interface
The application of this kind of digital
with manufacture or technology is particularly relevant to
prefabrication, as one can develop a
production and many system and adapt it to a specific set of
architects avoid the site and other contextual parameters or
client responsive conditions.
discussion...”
[Professor Thomas Bock, TU München, research
interview November 2010]
14 Future Proofing Schools | Prefabrication

15. Kuka Robotic Brick Assembly Robofold Concrete Printing @
Source: www.kuka-robotics.com Source: www.robofold.com Loughborough University
Concrete Printing @ Loughborough University
Digital Design> A Technology Timeline Digital Design Tools Future technologies
1940s Complexity of form, surfaces, structure Kuka Robotic Brick Assembly
Digital Fabrication and detail in design in recent decades
CNC systems created by the US Air Force has, by necessity, led many designers Accurate to 1mm, Kuka16 is a CNC robot
for fabrication of aircraft components. to be closely involved in the fabrication that can create unique brick wall panels.
“When an author processes and materiality concerns to Following in the footsteps of Uraguan
1970s | 80s enable their projects to be realised. Eladio Dieste’s elegant brickwork,
produces a drawing this technology can add beauty and
CAD CAM initially adopted by the Such involvement has required the performance to an automated cladding
which becomes the automotive and shipping industries. As incorporation of this information into system.
affordability increased, other areas of
information that manufacturing and industrial design
modelling and representation. This
approach has given designers control of Concrete Printing / Contour Crafting
drives the machine, it adopted the technologies. the digital information that can be used
directly in fabrication and construction, A full scale rapid fabrication system,
compresses the world of mid 1990s such technology allows for extremely
informing computer-controlled machinery.
design and fabrication accurate control over a plastic material.
Parametric modelling, building In turn, opportunities of feedback from Opportunities stem from the geometrical
into a single process.” information modelling (BIM) and mass fabrication, cost and performance freedom, single material construction and
[William Massie, 2010] customisation begin to emerge to analysis etc. can be integrated into an integration of function/services17.
transform both design practice and iterative design process, and prototype
project delivery. These technologies and scale models can be easily produced Robofold
“Automated technologies dovetail with CNC systems in Japanese to test and prove concepts.
prefabricated housing manufacture. Similar in ways to the Kuko robot, it allows
are major investments Increasing fabrication knowledge has for the automation of an infinite number
late 2000s reduced the gap between design, of unique metal folding operations
for manufacturers... so without need for expensive moulds and
Robotic systems allow for fully automated prototype and realisation. Digital
we need to be confident deconstruction of high rise buildings in information enables rapid prototyping press equipment18.
of scale models and is moving the
of a corresponding Japan. This urban mining approach is very
construction industry towards full-scale 16 http://www.kuka-robotics.com/
clean and materials can be reclaimed for
volume of turnover...” re-use. These principles also offer much automated fabrication. 17 http://www.buildfreeform.com/
[Jan Gyrn, Modscape, research interview March
potential for future construction. 18 http://www.robofold.com/
2011]
Prefabrication | Future Proofing Schools 15

16. Mass Customisation>
Consumer Choice Grasshopper Scripting from digital model
by David Lister, University of Melbourne
“Producing goods and An overview Benefits of re-use Key Opportunities
services to meet Architects have generally seen Creating a digital model in which • Architects playing a pivotal role
prefabrication as synonymous with mass the parameters of the design and in developing new processes and
individual customer’s products;
production which is perceived to be at construction process are retained after
needs with near mass odds with the one-off nature of architect the first implementation allows for • Creating innovative systems and
designed buildings. constant optimisation of all facets of designs adapted to the client, at
production efficiency.” production; building upon knowledge, reasonable costs and with high
[Tseng and Jiao, 1996] The concept of mass customisation experience and capabilities to increase quality construction;
changes that. suitability, efficiency and performance.
• Architects working with a much
“What these It combines the economies of scale of As requirements evolve, new units broader consumer base;
production processes with the latent can be introduced to the digital • Automating the fabrication process,
technologies offer capabilities of computer-aided design and model further increasing variety and to allow for multiple, high quality
is the potential computer-aided manufacturing (CAD/ therefore personalisation for clients and outcomes to be built from the same
CAM) technologies to offer greater choice ‘dynamic stability’ for designers and system at negligible cost;
to ‘try before you for the individual customer, improved manufacturers. • Minimising waste;
buy’ at all stages control of the total construction process,
and flexibility of assembly options. Thinking in terms of construction systems • Maximising performance.
of the development is also an important element of mass
Key Challenges
Flexible design and manufacturing customisation. This suggests a level of
cycle of a building, systems reduce the long term costs of interchangeability from a rich menu of • A perceived loss of architectural
from inception to production and logistics while increasing elements from which to compose new design freedom, architects feeling
personalisation and customer-perceived design solutions. they are confined within a ‘system’;
design, construction, value.
• A lack of common, open standards
demolition and Learning from the experiences of the for building components;
rebuild.” automotive and retail goods industries, • Need of increased software inter-
[Hampson & Brandon, 2002:22]
mass customisation could help architects operability across the industry;
to broaden their consumer base by • Current skills gaps in both the
providing increased financial accessibly. architectural profession and the
manufacturing sector.
16 Future Proofing Schools | Prefabrication

17. Case Study 1>
Het 4 Gymnasium
“This is a temporarily Project Overview Temporary School Design as the Enabler
sited school building Approach: 3D off-site | modular The Het4e Gymnasium - the Dutch The architect considered how the
equivalent to a grammar school - is modules could be separated and
that is moveable and Location: Amsterdam located in an area of Amsterdam that is reconfigured in a variety of different ways,
most importantly of a Client: City of Amsterdam undergoing major regeneration. to respond to a number of possible future
scenarios.
permament design and Architect: HDVN Architecten, Amsterdam The client believes quality schools are a
key regeneration catalyst, so proposed Coloured aluminium panels provide a
construction quality.” Manufacturer: URSEM BV, Wognum a two step solution: a temporary school colour explosion to the façade, giving the
[Arie van der Neut, HDVN] building for 5 years, followed by a school a joyous and playful appearance.
Date of Completion: 2008 permanent school building once the The timber rainscreen cladding provides
zoning issues had been resolved. texture, and the angled reveals give a
depth to the building.
Due to problems with the development
zoning plan, the school site is currently Integral to the timber cladding are hinges
zoned for temporary use. that allowed the rainscreen to be factory
finished; the sections that cover the
In the Netherlands, temporary buildings – modules joins can be ‘flipped down’ for
up to 5 years - are subject to less rigorous transport, then ‘flipped up’ to cover the
building codes, and the client initially joins at the completion of the installation.
approached architects HDVN to design a
temporary quality school for the site. A Modular Approach
Permanent Quality The separate modules that make up
the school left the factory around 85%
HDVN argued that using modular complete. Pre-installed services were
construction for a temporary school that ready for connection and final testing on
was moveable and re-useable justified site.
higher construction quality.
The school’s auditorium was created with
A core criteria for adopting the higher a frame and infill panel system, showing
quality approach was that the 5 year how one project can embrace a variety of
temporary building period coincided with prefabrication approaches.
time most students would be at school.
Prefabrication | Future Proofing Schools 17