BLDG 691K Lecture 1: Introduction to Modular and Off-site Construction PDF

Instructor: Sang Hyeok Han Associated Professor Department of Building, Civil, and Environmental Engineering, Concordia University  General Information – Course code: BLDG 6641: Modular and Off-site Construction – Lecture time: Monday, 14:45 – 17:30 – Loc...

Instructor: Sang Hyeok Han Associated Professor Department of Building, Civil, and Environmental Engineering, Concordia University  General Information – Course code: BLDG 6641: Modular and Off-site Construction – Lecture time: Monday, 14:45 – 17:30 – Location: H 507 – Instructor: Sang Hyeok Han Office: EV 6.223 Tel: 514-848-2424 ext. 3942 Email: [email protected] – Office hours: Contact to me through email for an appointment. ▪ Marker: Mizanoor Rahman ([email protected]) Moaaz Aly Aly Elkabalawy ([email protected]) 2 Introduce the benefits of modular and off-site construction - A production strategy of modular and off-site construction - Modular and off-site facility components and production processes - Concepts, methods and techniques in lean manufacturing to improve productivity and safety - Material waste management - Physical demand assessment and management in workplace design. We are going to learn the following topics: 1. How can we apply a manufacturing system and its necessary elements into construction industry? 2. How can we best handle and integrate the manufacturing philosophy into modular and off- site construction (MOC) domain? 3. How can we design modular components in buildings? 4. How to identify and eliminate the waste in the MOC manufacturing process for better productivity? 5. How to design worker-friendly workplaces to operate the repetitive tasks in the MOC manufacturing process for safety improvement? 6. More topics can be discussed. 3 Suggested Textbooks: Michael A. Mullens. (2011). Factory design for modular homebuilding. Constructability Press, First Edition, Winter Park, FL. Tapping, D., Luyster, T., and Shuker, T. (2002). Value Stream Management: Eight steps to planning, Mapping, and Sustaining Lean Improvement, First Edition, Productivity Press, NY. Dennis, P. (2016). Lean Production Simplified, 3rd Edition, Productivity Press, NY. Modular Building Institute (2015). Introduction to Commercial Modular Construction, Modular Building Institute Additional reading materials will be announced or posted on the course website Course website: Moodle 4 Course Criteria Criteria For graduate student Remark Assignments and 15% Two assignments Participation Term Project 25% -Submission date of (Mid-report: 5% mid-report: Mar. 3rd, Final report: 10% 2025 Presentation: 8%) -Submission of final report and presentation file: April 7th, 2025 Reading Report 10% Feb. 9th, 2025 (Tentative) Quizzes 17% Three quizzes 1st Quiz: 3% Jan. 20 2nd and 3rd Quizzes: each 7% Exam 33% Midterm – 12%, Feb. 17th, 2025 (Tentative) Final Exam – 21%, March 31st ,2025 Total 100% The dates for quizzes will be announced later in Moodle. 5 Evaluation Criteria for Reading Report 6  Description # weeks 1 Introduction of Modular and Off-site Construction 1 week 2 Wall and Floor framing design in modular and off-site construction 2 weeks 3 Factory layout development 2 weeks 4 Worker-friendly workplace design 1 weeks 5 Process improvement using Lean Manufacturing 2 weeks 6 Guest Lectures Not Confirm - Application and Trends of MOC in Canada by Dr. Jun, Ahn (NRC) 7 Midterm Exam Feb. 17th, 2025 Final Exam. March 31st, 2025 8 Term Project Presentation April 7th, 2025 The schedule of the guest lectures may be changed in accordance with the schedule of guest lecturers 5  Assignments – Collected on due date through Moodle. – Represent details and calculations/answers. Do not represent only answers – Submitted by a handwritten softcopy with a signed copy “Expectations of Originality” form on the due date. https://www.concordia.ca/ginacody/students/academic-services/expectation-of-originality.html?utm_source=redirect&utm_campaign=expectation- originality.html – NoT accept any submission after the due date described on the assignments Quizzes – Exact dates will be announced later in the Moodle. – Multiple choice, short questions and answers, calculation 8  Exam – Allow specific calculators allowed by Concordia University. – Cover lectures, handouts, slides, and assignments – Closed-book and closed-notes – Will announce detail information for online exam 9  Plagiarism - The most common offense under the Academic Code of Conduct is plagiarism which the Code defines as “the presentation of the work of another person as one’s own or without proper acknowledgement.” - This could be material copied word for word from books, journals, internet sites, professor’s course notes, etc. - It could be material that is paraphrased but closely resembles the original source. - It could be the work of a fellow student, for example, an answer on a quiz, exams, data for a lab report, a paper or assignment completed by another student. 10 - It might be a paper purchased through one of the many available sources. - Plagiarism does not refer to words alone- it can also refer to copying images, graphs, tables, and ideas - “Presentation” is not limited to written work. It also includes oral presentations. Computer assignments and artistic works. - Finally, if you translate the work of another person into French or English and do not cite the source, this is also plagiarism. Students must read not only academic conduct issues in the course outline but also the academic code of conduct after first lecture. (http://concordia.ca/students/academicintegrity) 11  Regular attendance is expected and encouraged Each student is responsible for all material and administrative instructions given during the lecture period. Instructions will not be repeated outside of class. Eating, chewing, talking, cell phone use or working on other assignments are not allowed Sleeping? It is all your responsibility to miss important contents, messages and announcement related to exams, quizzes, assignments and term projects. 12  First Quiz from 2:45 PM to 3:05 PM on Jan. 20th, 2025. Covers Academic code of Conduct Image: 1. The Academic Code of Conduct is the University's official policy on academic integrity. a. True b. False 1.Instructors, students and administrators are expected to be honest and responsible in their academic conduct and fair in their assessment of academic matters. a. True b. False  BCEE academic advisor Concordia Counseling and Development Advocacy and Support Services New Student Program Access Centre for Students with Disabilities Student Success Centre Financial Aids & Awards Health Services …… 15  Literature Review Wikipedia defines literature review as “a text of a scholarly paper, which includes the current knowledge including substantive findings, as well as theoretical and methodological contributions to a particular topic.” ▪ The purpose of a literature review is to: o Identify each work in the context of its contribution to understanding the current problems and trends being studied. o Identify the important works in your interesting topics. o And more. Source: https://en.wikipedia.org/wiki/Literature_review 14  Application of building information modelling in MOC. Process improvement of MOC Automation in MOC Process mapping in MOC Application and challenges of Industry 4.0 in MOC Lean methodologies and techniques for MOC Digitalization of MOC MOC scheduling Logistic methods and plans in MOC Site planning and layout in MOC Performance evaluation in MOC Etc. 17  You must represent a topic which supports to enhance some benefits of MOC Refer Journals: Journal of Construction Engineering and Management, Journal of Management in Engineering, Building Energy, Building and Environment, Journal of Industrial Ergonomics, Applied Energy, Automation in Construction, Advanced Engineering Informatics, etc. Please review at least ten (10) papers such as journals, conference. Maximum page is 5 pages with a single space except references. Feel free to use appendices if you want Font type: Times New Roman, Font Size: 12 pt. Submission Date: 2:45 PM, Feb. 9th, 2025 Reference format: Zhang, P., Harris, F. C., Olomolaiye, P. O., Holt, G. D. (1999). “Location optimization for a group of tower cranes.” Journal of Construction Engineering and Management, 125(2), 115–122. 14  Modular Building Institute (MBI) defines modular as a process in which a building is constructed off-site, under controlled plant conditions, using the same materials and designing to the same codes and standards as conventionally built facilities – but in about half the time. MBI, http://www.modular.org/HtmlPage.aspx?name=why_modular Modular building is units that form a complete building or part of a building, and includes the building envelop (Gibb 1999). Alistair G.F. Gibb (1999). “Off-site Fabrication: Prefabrication, Pre-assembly and Modularisation”, The Builder Group PLC 19  Off-Site Construction “Off-site construction is the planning, design, fabrication and assembly of building elements at a location other than their final installed location to support the rapid and efficient construction of a permanent structure” National institute of Building Science Prefabrication Construction Any building that has section of the structure built in a factory and then assembled on site can fall under the prefabrication construction Modular Building Institute (MBI) Modular Construction The building is constructed in separated box-like modules which are transported, then secured together on-site to form a whole. National institute of Building Science Panelized Construction The building is constructed in wall, floor, and roof panels which are transported, then secured together on-site to form a whole. 20  Off-site Construction Prefabrication Construction Modular Construction Panelized Construction Usually use light-gauge steel Mainly use wood, light-gauge 21 steel, and concrete  Installation on-site (westlock) Affordable Housing Building for Seniors (total five storeys). 1st floor constructed on-site and remaining floors constructed by modules. Module : 22 ft (6.7m) X 56 ft (17m) X 11ft (3.4m). Weight: 24.95 tons. Total 30 modules. Select three alternatives (crane types and models).Objectives Research Simulate various crane operations Choose the smallest capacity of a crane (Liebherr LR 1160). Expecting time to install modules was four days. Real time was two days. 24  Types of the MOC Reasons to adopt the MOC 25 Source: Mc-Graw Hill Construction (2011)  Impact on Project Schedule 26 Source: Mc-Graw Hill Construction (2021)  Impact on Project Budget 27  Reasons not to adopt the MOC Influence not to adopt the MOC in on-site 28  Modular construction has been used to build commercial buildings for more than 100 years. Modular construction started gaining popularity early in the 20th century due to two reasons: After the end of World War II caused the modular market to expand and evolve because of the marketplace, which used traditional building processes, could not handle customer demands from veterans that came back to America (Europe) and needed new homes. In the 1980s, cranes that had the capacity to lift 100 tons or more that modular building industry grew sharply, since large modules could be constructed and shipped cross-country. The modular building industry comprises various markets including offices, education, government buildings, healthcare, retail and commercial buildings, and military 29  Construction industry mainly uses: ✓ Design-Bid-Build (DBB) ✓ Design-Build (DB) ✓ Construction Management at Risk ✓ Integrated Project Delivery (IPD) Modular and Off-site Construction (MOC) mainly uses Bid-Design-Build (BDB) MBI (2015) Owner Architect/ MOC Site Engineer Company Contractor 18  Lump Sum Contract Unit-Price Contract Cost-Plus Contract ✓ Percentage Fee ✓ Fixed Fee ✓ Fixed Fee with a guaranteed maximum price ✓ Fixed Fee with a bonus and/or penalty ✓ Sliding Fee 18  Commercial General Liability Insurance -Protect the MOC company from bodily injury and/or property damage caused by accident or continuous exposure to some harmful condition Commercial Auto and Inland Marine Insurance -Essential insurance since modules are transported to on-site -Ensure replacement for modules, tools, equipment (e.g., cranes, forklifts, etc.) caused by an accident, theft, or loss during transport Worker’s Compensation Insurance Bond ✓ Performance bond ✓ Payment bod 18  Total time required for conventional building construction Phase 1 Phase 3 Phase 2 Phase 4 Design and Construction Bidding Close-Out Engineering of Building Total time required for Modular construction Time Saved (30-50%) Phase 3 Considerable Phase 1 Phase 2 Installation of Savings in Design and Fabrication of Modules on-site Time, Cost, Engineering Modules and Close-Out and Resources Phase 2 Site Preparation and 18 Development  Built to a lower standard of quality Only meet temporary needs (i.e., portable classrooms) Can only be moved once Do not follow the same building codes as traditional construction Fewer architectural design choices Too new of a construction process More? 34  Less site disturbance and material waste - Minimized workers, equipment and suppliers on-site Better flexibility and reusable material Reduced construction schedule - Completed 30% to 50% sooner than traditional construction Elimination of weather delays - 60 - 90% of the construction is completed inside a factory - Creating a faster and return on investment Safer construction - The indoor construction environment reduces the risks of accidents  Not efficient modular drafting design tools (ex. Multi-panels shop drawing and CNC code) Loss of productivity on a production line Lean, BIM, - manual and random works Ergonomics - poor factory control system etc. - unpredictable and disorganized scheduling Inefficient machine operation - Fully not meet requirements of modular construction Workers’ safety issues due to repetitive activities Required intelligent crane lift analysis for better safety and productivity Rivetting tool  Areas in Modular and off-site construction Framing On-Site Installation Design Sheathing Rigging Component Sheathing Productivity Design Crane support Layout Structural Framing Safety system Crane lift path planning & Optimal HVAC scheduling Scaffolding CNC Code layout and Crane selection & location Planning planning Modular and Off- Planning and scheduling Health & Safety site Construction Trailer planning & (Noise control and scheduling ergonomics) Truck planning & Workplace Design Performance Measurement scheduling Facility Layout Material procurement Continuous Process Management Improvement Factory operation Transportation Side view A_f C_v B_f D_v G_f E_v F_v H_b I_v J_v 37 H_v  Factory for better productivity and safety Planning and scheduling (sequencing of modules). Factory performance measurement (i.e., A process- oriented framework to evaluate and improve factory performance in modular construction) Process improvement by tracking and control to balance the factory. Facility layout and workplace design. Material procurement plan and scheduling. Ergonomic risk assessment and control (i.e., physical demand analysis). Noise exposure assessment. 38  H O W T O E VA L U AT E A N D P R E D I C T T H E MODULAR CONSTRUCTION PERFORMANCE Inte ty l Optimization Simulation Stochastic ili lig Deep Learning nab Lean manufacturing en t i Automation in process, a analysis, assessment, t design, and performance s measurement Su S m ar t Info Cloud-base tracking r mation system Computer-vision tracking & Quality assurance RFID BIM 39 40  Modular Building Institute (2015). Introduction to Commercial Modular Construction, Modular Building Institute. McGraw Hill Construction (2011). Prefabrication and Modularization: Increasing Productivity in the Construction Industry, McGraw-Hill. 42