P-DFMA Kit Of Parts- NG Bailey

Project Details

Project - P-DFMA Kit Of Parts

Sector - Commercial

Technology - Components

Company - NG Bailey

Product Overview

NG Bailey, along with Landsec, Bryden Wood, and Easi-Space, led a collaborative project to develop and test automated construction on a real site, and compare  efficiencies against traditional build. Through BIM we created a structural frame suitable for an office that could be manufactured offsite and assembled onsite using an automated assembly. Following competitive tender, we became involved with The Forge in December ‘19 to develop the MEP KOP, with onsite install from July ‘21.

Our offsite team developed the entire internal building services distribution and associated architectural finishes as a KOP, manufactured offsite and installed using a P-DfMA approach (adopted by UK Government and the focus of Construction Innovation Hub). We designed 5 Cat A MEP cassettes in various sizes, including elements such as pipework, FCUs, grilles, lighting, sprinklers, acoustic rafts, ceiling modules, and ductwork kits.

The KOP provided 95% of high level install. The KOP can be emulated across Landsec’s future estate for reduced design and build periods, improved facilities management, saving costs and reducing environmental impact. Key to maximising the benefits of offsite solutions is engagement of our experts early. On The Forge, we collaborated with the design team focusing on solutions that maximised the potential benefits of a PDfMA solution, two years prior to onsite construction. We prototyped a standard 9m x 9m planning grid combining fabricated standardised steelwork components, reusable formwork and in-situ concrete that can be installed using an automated process.

We knew if successfully scaled and deployed, The Forge would become the first in the world to be built this way. Collaboratively, we set ambitious targets for the prototype to deliver improvements compared to a traditional steel and concrete structural solution. Targets included:

• 33% cost saving

• 25% assembly time reduction

• 40% construction productivity increase

• Improved H&S. The prototype results demonstrated targets were possible.

This innovative working was substantially more efficient and productive from day one. The Forge presents a flagship project for driving innovation in construction,  accelerating change in how we develop our built environment for generations to come. “The Forge is setting new industry standards for sustainable and cost-effective construction. The P-DfMA approach we have taken to design and construction will transform how offices are delivered in the future. What we learn at the capital’s most innovative construction site will shape the way we approach future projects and help change the industry for the better.” Neil Pennell, Head of Design Innovation and
Property Solutions, Landsec.