Supported by

Your guide to specifying Modular Buildings

Your guide to specifying

Off-site
manufacture
Maximising value and
minimising risk
 Supported by

Your guide to specifying Off-site manufacture

Your guide to specifying

Off-site manufacture
Maximising value and minimising risk
 Contents
1 Executive Summary 4

2 Introduction 5

3 The Traditional Approach 6

4 Avoidable Pitfalls 7

5 Early Involvement of the Off Site Manufacturer (OSM) 8

6 Design & Specification 9

7 Key Requirements for a Performance Specification 13

8 Conclusions 14

Appendix A Exploit Supplier’s Capabilities 15

Appendix B Useful Sources of Information 17

Appendix C Preparing a Tender 18

Courtesy BWA

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Your guide to specifying Off-site manufacture

Contributors
Doug Waters - Lead Author BAA Ltd
Nigel Fraser BAA Ltd
Richard Kelly BAA Ltd
Richard Ogden Buildoffsite
Brook Nolson Britspace
Damian McCoglan Terrapin
David Appleford Acermetric
Tom Weaver Yorkon
Peter Warner Yorkon
David Johnson Yorkon
Anna Winstanley Laing O’Rouke
Stephen Hough Crown House Technology
John Stehle Crown House Technology
Paul White Crown House Technology
Bassum Burgan SCI
Michael Lealan NG Bailey
Paul Jackson NG Bailey
Frank McLeod Bryden Wood McLeod
Jeremy Smith Wilson James
Graham Townend Framing Solutions
Eric Dean Panaloc

Abbreviations used:
BRE: Building Research Establishment
CIRIA: Construction Industry Research and
Information Association
GA: General Arrangement drawing
IMMPREST: Trademark derived from: Interactive
Method for Measuring PRE-assembly
and STandardisation
M&E: Mechanical and Electrical services
OSM: Off Site Manufacture
RHA: Road Haulage Association
SCI: Steel Construction Institute.

Your guide to specifying Off-site manufacture. Maximising value and minimising risk
R Kelly, BAA
Revision 2, 17 August 2009

3
1 Executive Summary
Buildoffsite and BAA recognised a need for guidance to help It is beneficial to introduce design freezes into the programme as
client and specifier organisations to get best value from off site these will help to mitigate the effects of any late design changes,
building suppliers. Generally, it has been observed that tender which may not be as easy to incorporate when using an offsite
packages are sent out with too restrictive design information solution.
and too late in the design process. This inhibits the off site
suppliers from fully exploiting their skills and expertise to deliver The offsite specialist should be involved during the design stages,
efficient economic solutions to meet clients and specifiers working with the designers, to ensure that the design is not
needs. taken to a stage where it restricts the benefits that can be
brought through the use of offsite manufacture. An integrated
These guidelines aim to address this problem by advising when in the design team will generate most value.
design process to involve off site manufacturers and to what level of
design projects should be taken before tenders or requests for The client should be satisfied that the off site supplier has the
information are issued. appropriate level of competence required. This is difficult to
establish without carrying out an indepth audit by a
The guidelines are the result of two workshops and a series of follow manufacturing specialist. Accreditation schemes such as the
up meetings which have been held at CIRIA using the Buildoffsite Buildoffsite Lloyds Register will help
membership. This has provided knowledge and expertise to advise on
the level of information that is required and when involvement can
most effectively be used in the project process.

There are a number of conclusions which can be drawn as a result;

Initially, design should be kept outline, flexible and should not be

too detailed. Ideally the design should be limited to performance
specifications with clear definition of the purpose of the building
and its functionality, supported by basic layouts, plans and
elevations. Courtesy BAA

It should be understood at the start of the project that offsite These guidelines provide practical advice which may be applied to a
manufacture has implications for the design, manufacture and wide range of projects, from designing and constructing complete
assembly programme. Project programmes must reflect these buildings to designing and manufacturing the service modules which
variances in stage durations from the start as late adoption of fit within them.
offsite manufacture may adversely affect completion dates whilst
early adoption can pull it forward. BAA and Buildoffsite wish to thank all those who took part in the
development if these guidelines, providing information, thoughts,
comments and guidance.

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Your guide to specifying Off-site manufacture

2 Introduction
It is generally accepted that off site manufacture (OSM) can in
many circumstances present a significantly beneficial alternative
to traditional on site construction. To achieve the optimal level
of intervention by the client and their consultants it is necessary
for the OSM to be allowed to contribute their expertise to bring
the full benefit of OSM early in the project.

To investigate the correct level of intervention and the levels of

specification to be provided in tenders a series of workshops have
been held by BuildOffsite and BAA Limited to consult with the off site
industry.

This is the output from those workshops and it is hoped that their
use by clients and consultants will encourage increased submissions
to tenders invited by construction clients and ensure more effective
use and continued growth in the off site market.

Benefits that may be expected from OSM:

 Shorter overall programme
 Predictability & reduced risk
 Lower project cost
 Better & consistent quality
 Less impact on site operations
 A safer project
 Reduced material waste
 Reduced construction traffic on site

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3 The Traditional Approach
While the informed client may have an excellent understanding Relevant site information
of what they want their building to do and how they want it to  Location
be delivered this can miss the opportunity of further success by  Site constraints & restrictions
using offsite manufacture. Too much constraining information  Site access
included in a tender based on pre-conceived construction  Hours of working
solutions will restrict the benefits that the OSM can bring to the  Incoming services
project  Adjacent structures

Whilst there are a number of procurement approaches, typically the This level of information is generally acceptable for a traditionally
client and their consultants will produce a package of information for constructed in situ building but could become too detailed to allow
a tender design up to ‘scheme design’ as a minimum which will the OSM to bring their product benefits and knowledge to the
include; project. Once the design has progressed past outline scheme design
any OSM will have to redesign the project to suit the constraints of
Purpose of the building their modular system. All methods, whether steel or timber framed,
 Temporary, permanent or re-locatable will have limitations on spans, loadings, numbers of floors and
 Required lifespan or number of moves transportation. This is a wasteful use of the consultants and the
 Access by customers or staff only OSM’s resource and hence the client’s money, while restricting the
 Defined occupancy levels useful benefits that offsite manufacture can bring to the project.
 Footprint, GA’s and elevations Involving the OSM too late in the project results in more
 Room relationships and data sheets preconceived ideas which then require re-assessment.
 Critical restraints
 Floor loading requirements
 Foundation designs
 Ceiling/storey heights
 Internal environment criteria
 Full internal finishes specification
 External finishes specification
 M & E requirements

Budget & Time

 Budget expectations
 Timing expectations

Design
 Clear ambitions for final design and visual profile for the
project
 Local authority planning constraints
 Consideration of future proofing

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Your guide to specifying Off-site manufacture

4 Avoidable Pitfalls
The offsite manufacturers who were consulted in the The result of these items is a high proportion of tenders returned
preparation of these guidelines have suggested that the incomplete, or projects which when completed, fall short of client
following points are the most prevalent causes of tenders being expectations, bringing the OSM industry into disrepute. This may
returned incomplete or project resources not meeting client’s cause both clients and consultants to doubt the benefits which OSM
expectations. can bring to future projects.

 Over design by consultants

 Lack of clarity in performance standards
 Too much detailed design too early
 Being over prescriptive in non-essential areas
 OSM supply chain capabilities & cost drivers not understood
early enough
 Consultants trying to design for manufacture without the
specialist skills
 Budget constraints ignored
 Practicality of build ignored, is it suitable for OSM?
 Engineering constraints overlooked
 Client standards (especially M&E) which are not appropriate

Courtesy BWA

7
5 Early Involvement of the OSM
If it is agreed that a project may benefit from off site The following items have been raised as being of importance
manufacture then early involvement of potential OSM suppliers to the off site manufacturers
is vital if the design is not to be allowed to go too far down the  Purpose: the need for a clear definition of the solution’s
traditional construction route. Involvement should be as early purpose is considered paramount in the completion of a
as possible and can start by a review of the strategic brief specification. Above all other concepts the importance of a
including the items listed below; simple performance specification that does not include
prescriptive pre-design is key
Strategic Briefing Stage  Manufacturing Concerns: design freeze and exploiting
 Assess strategic brief with client standard elements can be important points of compromise
 Identify key drivers for success that must be negotiated between clients and the potential
 Identify constraints and risks off site manufacturing suppliers
 Agree process and decision making for design brief  Contextual Requirements: the situation within which and
development and approval surrounding the solution to be proposed should be correctly
 Does the project release the inherent benefits OSM can articulated if an effective and efficient product is to be
bring? feasibly presented
 Costing Considerations: clients need to be made aware of the
Some clients may feel that involvement of the OSM at this stage is costing implications of off site solutions. Understanding the
not appropriate and will detract from the production of an unbiased impacts of risk, prelims, programme etc not just considering
strategic brief. If this is the case, then the activities listed below capital cost except where this is the key driver
should be assessed for their influence on the project and to prevent  Simplicity is vital: keep the design simple and flexible, this
excessive amounts of unsuitable design work being carried out before does not mean boring and box like, to allow the OSM to bring
the offsite manufacture route has been fully investigated. the benefits of their products to the project. Define level to
visual “flair” required
Outline, Detailed and Final Proposal Stages
 Costs: clients are likely to benefit from considering the whole
 Identify opportunities and aspirations for design for
life cost of a building
manufacture and assembly, agree strategy
 Agree process and timing for cost verification and relate
these to design process
 Collect historical cost data from similar projects from
potential off site suppliers
 Identify opportunity and benefits in early engagement of
supply chain
 Identify skills required and who should provide (consultant
versus potential supplier)
 Develop processes for seamless engagement of consultants and
suppliers – agree deliverables and processes for cost control
 Identify site logistics and buildability issues to inform option
selection and design for manufacture and assembly strategy
 Agree phasing strategy

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Your guide to specifying Off-site manufacture

6 Design & Specification

The key to gaining the benefit of OSM is to provide a Do’s
performance specification which has ideally been produced in
consultation with the OSM supply chain through early  Share ambitions with the OSM industry
involvement during brief production and proposal development.  Be open & honest
 Work with the industry to raise standards & develop products
There needs to be a shift of emphasis away from design onto  Keep specifications simple
purpose and performance. This allows the OSM to tailor the design to  Employ consultants who understand & embrace OSM
suit their method of off site manufacture, to allow maximum benefit  Look for value for money, use tools like IMMPREST to assess
from their knowledge of module sizes, configurations, spans and benefits
loadings and transportation restrictions. The OSM market seems to  Be receptive to supplier ideas
be developing into two distinct streams with manufacturers who  Use consultants for peer review
produce standard products and those who produce mass customised  Reward success
products.  Use design reviews and a change control process
 Give value to speed, quality, safety, waste and predictability
The design requirements will indicate one stream or the other. The  Use off site companies with modern manufacturing methods
parts of the design which affect the client’s brand or signature can
be protected by being specified. Other parts of the performance Don’ts
specification, acoustics, thermal, lighting levels etc can be set as
levels of performance which need to be met but which the OSM may  Be over prescriptive too soon
design how they are achieved.  Allow consultants to over design
 Try to design for manufacture without understanding
Any pre-design that features in a specification will most likely capabilities and cost drivers
immediately disadvantage the OSM community, due to the design  Select the off site supplier on cost alone without
consultant’s lack of expertise in the field of offsite manufacturing. understanding their critical capabilities

Solutions to design challenges have often already been addressed by

OSM’s.

Courtesy NG Bailey

9
 Specification Contents Purpose and functionality are the key to effective solutions, for
Any specification should inform as to the purpose and the use that a example, forecourt check-in facilities at an airport may well be sized
solution will satisfy rather than providing a detailed design that tells to suit check-in desks and queuing arrangements. This information
the manufacturer how the solution should be fabricated. would be key, allowing the manufacturers to understand how layouts
could be made to work within standard module sizes.
Specifications should be made as simple as possible, outlining the
solutions purpose and how it will be utilised, not how it should be How the solution has to be integrated with existing facilities is
designed and manufactured. This requires either earlier involvement important to allow tolerances to be included in the design and again
by the manufacturer in the design stage or design consultants who allowing the manufacturers to understand what can be standard
understand the OSM’s processes. modules and what needs to be bespoke.

An aspiration is for the specification to be a single A4 sheet which Programme

identifies internal & external finishes, environmental concerns and Programming should be realistic. Detailed design needs to be
project specifics, not a full design that informs the modular builder advanced early and then frozen. Preparation for offsite generally
how to do their job. Manufacturers do not require details on how takes longer due to the level of design information required prior to
solutions are to be constructed. production, start on site is later but work on site is of shorter
duration. Tender periods need to be a minimum of four weeks to
allow the OSM to properly work up their offer. Two stage
development of an offer should be considered.

M & E examples:

Traditional Off-site Difference

Project Category Benefit
(weeks) (weeks) (weeks)

Off-site and
Office pre-construction
2 8 +6 -300%

On-site 7 2 -5 +71%

Overall project 9 10 +1 -11%

Off-site and
Hospital pre-construction
17 22 +5 -29%

On-site 140 106 -34 +24%

Overall project 157 128 29 +19%

Source: buildoffsite business case studies 001 & 002

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Your guide to specifying Off-site manufacture

Compliance
Courtesy Buchan
In the case of statutory compliance it is suggested that only
exceptions, where variations from the standards/regulations are
required, should be included. Otherwise compliance is to be as per
current standards/regulations and is taken as read.

Contractual Arrangements
Contractual and commercial arrangements of the tender must be
clear including options for purchase, lease purchase or hire plus
maintenance requirements where appropriate. Some suppliers may
ask for stage payments ahead of a traditional build programme.

Future Flexibility
Relocation requirements should be realistic and specific. Extra cost is
added to a solution by specifying a requirement for relocation, which
may never actually be required. Consideration should also be given as
to whether requirements for future adaptability, extension and
modification are really necessary.

It is more cost effective to build in future flexibility during

manufacture than as a post construction modification but these will
add cost to the final solution which may be completely unnecessary.

For example, at BRE’s Innovation Park a show house has additional

support structure built in to allow for the installation of a mobility
hoist from bedroom to bathroom should it be required at a later date.
Consultants
Inclusion of this support work during manufacturing would be a
The consultant’s role should be to interpret the specific requirements
fraction of the cost and disruption of a post completion installation.
of the client and produce a performance specification. Current
practice is for a client’s consultant to complete a comprehensive
Logistics
specification including a bespoke design for every solution. For
The importance of logistical considerations is not to be
example structural engineers should only request specific loadings
underestimated. Information about site restrictions and integration
and provide information on ground conditions. Most OSMs have in
with existing facilities is essential and should be fed into the
house design capability which is 3rd party verified.
specification as early as possible. The complexity of the logistics
demands professional expertise which should be the responsibility of
the supplier/manufacturer.

11
 Additional duplicating of consultancy is considered to be inefficient, Handover information
leading to redesign on the part of the OSM and not allowing them to OSMs have accurate 2D drawings and 3D models of their products.
use their standard designs and manufacturing expertise. This combined with a well controlled manufacturing process enables
delivery of very representative “as built” information, which clients
Design Freeze are encouraged to ask for.
A complete design freeze such as that used in the manufacture of
automobiles on receipt of a customer order would be necessary for Keep it simple and:
off site manufacture to be fully effective. However, it would be  Involve OSM early in the design process
unrealistic to believe that a final design could be decided at a very  Allow flexibility to accommodate module design & structure
early stage and remain unchanged throughout the construction  Keep specifications concise & clear with scope for
process. Instead a suggested phased freeze might be a more development by supplier within agreed parameters
achievable target.  Use the capability of the supply chain
 Understand that every supplier is different
Clients also need to be made more aware, at the time, the impact of  Be prescriptive only where you must; finishes, claddings,
changes to a design, so that time and cost overrun on a project could acoustics, bomb blast resistance etc
be easily attributable and not come as a surprise to the client.  Avoid wasteful design activity
Further to this, clients should be made aware of what are the largest
cost drivers in modular manufacture so that decision making is more
informed. Clients should state what is set in stone and must be
adhered to, for example client’s colour schemes and branding.

Clients should be careful to select off site manufacturers who

operate modern manufacturing methods. Although progressive
design fixity is still going to be important, they will be the ones with
most agility to respond to detail change, lead time changes and
quantity design

Courtesy BWA

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7 Key Requirements for a Performance Specification

The following list of key requirements should be considered for In addition the tender will need to confirm the type of contract, the
inclusion in any performance specification issued for projects to appointment of principals (planning supervisor, clients agent,
adopt off site manufacture: architect, and engineer etc) and details of cost and programme
targets. Commercial arrangements for the tender should also be clear
 Requirements (usage, quantity, quality, true design life) stating options on purchase, lease purchase or hire.
 Criteria associated with the site, including location
 Limiting dimensions and volumes
 Critical functional relationships
 Service Requirements: electricity, gas, water, sewerage, fire
 A guide to cost and programme
 Strengths and forces: imposed loads, exceptional loading
 Cladding preference and thermal performance
 Fire performance
 Acoustic performance, internal & external
 Logistic requirements: flat-pack/space frame, transportation,
restrictions, speed of erection, erection requirements
 Specific interfaces
 Security requirements
 Finishes required
 Sustainability – energy targets and materials use
 Maintainability and hand over information
 Re-locatability

Courtesy Caledonian
Courtesy Southern Housing Group

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 8 Conclusions
The following simple conclusions can be drawn;  Issue performance specifications, don’t be too prescriptive
too early in the process
 Involve the offsite manufacturer in the design process during  Understand the effect of offsite manufacture on the design,
outline, detailed and final proposal stages manufacture and assembly programme stages and make
 Understand the cost drivers sensible allowances
 Provide clear definition of the purpose of the building and its  Allow professionals to manage the logistics
functionality  Programme in phased design freezes and understand the
 Understand and fully cost the benefits and risks of offsite implications of late design changes
manufacture  Don’t allow design work to be duplicated (consultant/OSM)
 Keep design simple & flexible, but not boring, to maximise
benefits from the OSM
 Don’t take the design too far or make it too detailed and
don’t try to design for manufacture
 Assess the critical capabilities of the off site suppliers that
are intended to be used (NB the Buildoffsite Lloyds Register
accreditation scheme has been established to assist clients
select the best off site suppliers)

Courtesy BWA

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Appendix A Exploit Supplier’s Capabilities

It was suggested by the OSM suppliers involved in the Dimensional Planning
workshops that an awareness of the current products available The dimensions of the finished project are critical to the success of
on the market and the associated details would be of great value the use of modular construction and OSM.
to design consultants and to a slightly lesser degree, clients and
their project managers. The design should give due consideration to:

Other useful sources to provide further guidance are manufacturer’s  The planning grid for internal fit out
design guides, e.g. Yorkon and design guides provided by the industry  Transportation requirements, including access
sectors: steel, timber, concrete.  Building form, as influenced by its functionality
 Foundation tolerances
The following information is generic with the exception of the table  Production controls
of sizes which will ultimately vary with manufacturer.  Alignment with external dimensions of cladding
 Repeatability in modular manufacture
Types of Modules
Modules can be manufactured and delivered in a number of different
formats to suit the needs of the client and the project constraints.

The options typically include:

 Four-sided modules
 Partially open-sided and open ended modules
 Open-sided (corner supported) modules
 Mixed modules and planar floor cassettes
 Modules supported by a primary structural frame
 Other module types
 Stair or lift modules
 Non-load bearing “pods”
 Open floor modules

15
 Modular dimensions
Internal Internal module Internal module Ceiling floor
Application
wall height (mm) width (mm) length zone (typical)

Study bedrooms 2400 2500–2700 5.4 to 6 m 300 mm

Apartments 2400 3600 6 to 9 m 450 mm

Hotels 2400–2700 3300–3600 5.4 to 7.5 m 450 mm

3000–3600
Schools 2700–3000 9 to 12 m 600 mm
open-sided

Offices 2700–3000 3600 6 to 12 m 600–750 mm

3000–3600
Health sector 2700–3000 9 to 12 m 600–750 mm
open-sided
Source: RHA

Transportation and Logistics Movement of modules of different widths requires different police
Not only do projects need to consider designing to suit where notices, escorts and additional crew as listed below for the UK:
possible generic module sizes but also for the restrictions on
transportation and site logistics.  Modules exceeding 2.95 m width require two days police
notice
 Modules exceeding 3.5 m width require a driver’s mate and
two days police notice
 Modules exceeding 4.3 m width require police escort
 Maximum practical height of the load is 4.95 m although
there are no legal height restrictions on UK roads.
 Standard container vehicles are typically 6.2 m or 12.2 m
long; they can delivery one large or two small modules
Source: RHA

NB “Air suspension” equipped vehicles may rise when in motion

causing the load height to increase

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Your guide to specifying Off-site manufacture

Appendix B Useful Sources of Information

Buildoffsite
www.buildoffsite.com

Buildoffsite
Glossary of Terms
www.buildoffsite.com

Loughborough University
IMMPREST Toolkit
www.immprest.com

SCI
Case Studies on Modular Steel Framing
The Steel Construction Institute, ISBN 978 1 85942 095 9

Gibb, A G F
Off Site Fabrication
Whittles Publishing, ISBN 978 1 87032 577 6

Lawson, R M and Grubb, P J

Modular Construction Using Light Steel Framing: An Architect's Guide
The Steel Construction Institute, ISBN 978 1 85942 096 6

Department for Education and Skills (now Department for Children,

Schools and Families)
Toilets in Schools
DFES 00365 2007, ISBN 978 1 84478 925 2

Offsite Magazine
Published annually by Building Magazine in association with
Mtech

17
 Appendix C Preparing a tender
Flow Chart to help create a concise tender for issue to Offsite
Manufacturer

Have the criteria to

decide modular against No Complete
traditional been assessment
assessed?
Yes

Have the key drivers Logistics

for OSM been M&E
identified? Sustainability
Value
Speed
Quality
What are the risks and Labour
constraints? Site access

What will the building

be used for? Ceiling height
Finishes
Re-locatability
What absolutes are Interfaces
required? Maintainability

Loadings
Fire rating
What are the Acoustics
variations from normal
standards?

Concise tender for issue

to potential OSM’s

18
Your guide to specifying modular buildings: maximising value and minimising risk
Buildoffsite and BAA recognised a need for guidance to help client and specifier organisations to get
best value from modular building suppliers. Generally, it has been observed that tender packages
are sent out with too restrictive design information and too late in the design process. This inhibits
the modular suppliers from fully exploiting their skills and expertise to deliver efficient economic
solutions to meet clients and specifiers needs.

These guidelines aim to address this problem by advising when in the design process to involve
modular manufacturers and to what level of design projects should be taken before tenders or
requests for information are issued.

The guidelines are the result of two workshops and a series of follow up meetings that have been
held at CIRIA using the Buildoffsite membership. This has provided knowledge and expertise to
advise on the level of information that is required and when involvement can most effectively be
used in the project process.

www.buildoffsite.com