Offsite and Modern Methods of Construction - Kier Group
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Kier Group Offsite and Modern Methods of Construction
Contents
Contents
4 What is offsite construction?
6 Why build offsite?
8 Our capability
10 Our approach
11 The Choice Factory
12 Collaborative partnerships
13 Award-winning
14 Platform design
16 Our experience
18 Evolution of modern methods of construction
20 The Hoxton, Southwark
22 Northampton Waterside Student Residences
23 Windlesham School
24 Project Capella
26 R7, King's Cross
27 FA Parklife
28 ProCure22
30 Sainsbury Wellcome Centre
31 HMP Oakwood
32 M6 Smart Motorways
34 DTTCP Lyneham
2 3
What is offsite?
What is offsite construction?
Bringing a manufacturing mindset to the design and construction of
buildings and infrastructure
Offsite manufacture and modern Offsite construction incorporates a variety of Bringing a manufacturing mindset to the
methods of construction can be defined innovative approaches to construct buildings design and construction of buildings and
as the design, planning, manufacture and infrastructure that result in increased infrastructure, we adopt a Design for
and pre-assembly of construction efficiencies and improved productivity. This Manufacture and Assembly (DfMA)
can mean anything from completely modular approach, which draws on a range of
elements or components in a factory
builds to the prefabrication of individual suppliers and systems to design a scheme
environment, prior to installation on components, such as service risers and using manufactured components for ease of
site at their intended, final location. rollout reinforced floors. assembly on site.
As the largest regional builder in the UK, A DfMA solution can deliver improved
Kier has extensive and diverse experience in efficiencies through the use of repeatable
the use of these methods of construction; components and processes, achieving a
moving the assembly of building higher quality product at lower cost and in
components into a factory environment. less time.
HIGH
EFFICIENCY 20% EFFICIENCY 40%
Proportion of pre-manufactured value
VOLUMETRIC MANUFACTURED
Standard solution, Bespoke solution,
Standard process Standard process
EFFICIENCY 0% EFFICIENCY 10%
Traditional vs Manufactured
Chart showing different construction
TRADITIONAL COMPONENTS solutions, from highly efficient manufactured
projects that use standard processes to
Bespoke solution, Standard solution,
deliver bespoke solutions, to the more
Bespoke process Bespoke process
common component-led projects that use
standard components within a bespoke
construction process.
LOW
Diagram from ‘Delivery Platforms for
Government Assets’ by Bryden Wood.
LOW Proportion of projects using modern methods of HIGH
construction
4 5
Why build offsite?
Why build offsite?
Improving productivity, integration and collaboration
The future of construction is changing At Kier, we have seen first-hand the benefits
and Kier is in a leading position to drive that can be derived when an offsite
this transformation. As part of the approach is well executed. The greater the
Budget, the Treasury announced in amount of prefabrication taking place offsite
the greater the potential benefits.
2017 that the UK Government would
use its purchasing power to drive
modern methods of construction
across capital projects in areas such as
education, transport, defence and
health to drive improved productivity.
Programme & logistics Quality
Offsite construction can significantly reduce the site Understanding the factory environment is key for a
programme, as components and assemblies can be seamless transition from factory to site. Working closely
manufactured concurrently in multiple locations. with suppliers, Kier undertakes regular visits to
Unaffected by weather conditions or other trades, factory manufacturers' facilities to ensure close quality control
assembly provides certainty of delivery. Installation is over production. Produced through established and
also much faster and all associated travel implications reiterative processes, offsite manufacture can provide
for secondary materials and labour can be vastly increased levels of accuracy and reduced defect
reduced, improving site logistics. variability, leading to a reduction in whole life costs.
Building on progress made to date,
the Department for Transport, the Safety Environment & sustainability
Department of Health, the Department
Factory fabrication allows significant use of automation By constructing building elements at a fixed facility,
and appropriate tools and handling methods, with work on-site waste can be virtually eliminated and any waste
typically undertaken at bench height. This offers an produced can be controlled and recycled. Careful
for Education, the Ministry of Justice opportunity to address some of the fundamental causes
of accidents, including lifting and falls from height, by
programming ensures efficient production and units can
be designed to maximise the use of space in delivery
and the Ministry of Defence will
reducing the number of trades on site, reducing the need vehicles, reducing carbon emissions. Site noise and dust
for scaffolding, as well as reducing manual handling and produced by on-site cutting and cleaning can also be
materials storage. removed.
adopt a presumption in favour of
offsite construction by 2019 across
suitable capital programmes, where it Cost Productivity & resources
represents best value for money.
Early engagement with specialist contractors to produce Productivity within manufacturing is significantly higher
an advanced design earlier in the process drives out risk than the construction industry. A reduction in the
allocations and leads to improved cost predictability. The number of workers required on site and access to a
use of standardised components can give economies of significantly wider labour pool away from site, reducing
scale, particularly when consistently applied beyond a the number of people on subsistence during the working
Philip Hammond, Chancellor of the Exchequer
single project. Rapid delivery also provides financial week.
benefits, improving cash-flow and offering developers a
faster return on investment.
6 7Our capability
Our capability Offsite specialisms
Our consistent and increasing use of offsite
manufacture spans multiple sectors and
Volumetric
geographical locations across the UK.
Volumetric or modular units are large building
elements can be steel or timber-based and are
From major mental health and We have driven change on numerous pre-fitted with electrics, plumbing, heating,
custodial establishments incorporating schemes, substituting traditional build doors, windows and internal finishes and
thousands of precast components to methods with offsite manufacturing and commissioned prior to leaving the factory. Units
collaboratively developing alternative design can include bathroom pods and plant rooms.
smaller offsite elements such as
solutions through early engagement with our
bathroom pods, prison cells and
clients and supply chain.
education facilities, Kier is committed
to using new technologies to provide
cost effective, sustainable solutions for
our clients.
Steel framing systems
In 2018 Kier delivered over 1.6bn worth of We use pre-panelised light steel framing
projects featuring offsite construction; from systems for a wide range of building types, from
major mental heath and custodial schools and hospitals to hotels and commercial
establishments incorporating thousands of offices. Panels are delivered in sequence to
precast components to smaller offsite ensure a seamless assembly process and can
elements such as bathroom pods, unitised be pre-boarded prior to delivery to site.
facade systems and modular M&E.
Engineered timber
Engineered timber, such as CLT, glulam and
SIPS, is highly sustainable and acts as a natural
carbon store. Panels are glued together in layers
for strength and fabricated to precise
measurements to form load bearing walls, roofs
or floor panels, with pre-cut openings for
windows and doors.
Precast concrete
Precast offers a durable solution for all building
types and infrastructure. Assembly is fast and
elements can include the structural frame,
columns, beams, unitised façades and flat
slabs. Openings for MEP are designed in and
precast at manufacture.
Prefabricated MEP
Multi-sevice modules such as prefabricated
risers, services runs and trench heating are
packaged or skid-mounted as pre-assembled
units, simplifying installation and providing far
greater quality control.
8 9Our approach The Choice Factory
Early engagement and integration Where your choices define the factory,
not the factory dictating your choice
Offsite not only allows us to deliver At Project Capella we brought together
projects faster, more safely and to offsite specialists and our structural
better quality standards, it also allows engineers very early, during RIBA 1 and 2, Rather than having a uniform solution
us to form an integrated team much providing a platform for their creativity and dictated by a factory, Kier provides a
confidence to invest in new technology and choice of factory-based solutions from our
earlier in the process. Collaboratively
construction methods. This resulted in an extensive and diverse supply chain. In this
undertaking early design stages with innovative hybrid solution of precast and
our supply chain enables greater way, the expert knowledge and experience
insitu concrete that met the strict vibration
engagement from all parties and, criteria of the laboratory and allowed for a of our people allows us to provide clients
consequently, better results. rapid build. Bringing specialists together with impartial advice as to the best
early allowed the concept frame to be tested solution, from the full spectrum of
When offsite is considered from the outset
for performance before orders were placed technologies available.
we are able to maximise the benefits,
and designs finalised.
supporting SMEs to develop and deliver Engaging with us early allows us to fully explore
innovative solutions to derive best value for It's a process that works and is admired these options with you and with our supply
our clients. Engaging early with us externally - Construction News described it chain, maximising the benefits that can be
encourages collaboration, integration and as “a template for the future of our realised.
allows us to hit design freeze dates and industry”.
To find out more visit:
procurement milestones to secure
production at the right time. www.kier.co.uk/choicefactory
This integrated approach leverages our
ability as a Design & Build specialist. We’re
aware of the details and decisions that are
needed as the project moves through design
stages, so we drive a journey that gives the
entire team a deeper understanding of
project aims.
Steel framing Engineered Precast Prefabricated
Volumetric
systems timber concrete MEP
Digital technologies
Fundamental to guaranteeing the Offsite also brings an increased focus on
success of our offsite approach is the accurate sequencing and enhanced logistics
use of digital tools. BIM and offsite for the delivery and installation of
construction go hand in hand with the pre-manufactured components. We model
topography, environmental constraints and
Government’s aims of reducing costs
site interfaces to inform logistics planning
through increased productivity and and use 4D simulations to give greater
advanced data management. clarity to operatives for a seamless
With increased emphasis on early installation sequence, allowing teams to
engagement and the requirement to get keep pace with the rate of assembly. PROJECT INTEGRATOR
things right first time, BIM encourages the Our internal common data environment,
consideration of offsite solutions as early as BIMXtra, and digital component libraries
possible in the planning process. It allows allow us to digitally manage and track all
SUPPLIERS CONSULTANTS
teams to test the implications of design project information. Tagging and logging
changes virtually, before any work takes each asset digitally ensures all information
place on site, ensuring the model is is kept in one place and allows us to track
analysed for integrity, quality and physical each components' journey to its intended
safety, as well as highlighting any clashing final location and beyond into facility
components before commencing management. BESPOKE SOLUTION
manufacture.
10 11Collaborative partnerships
Influencing positive change within the industry
Our commitment to offsite and modern At Kier, we are constantly looking at ways to We recently responded to the House of
methods of construction extends bring new products, processes and Lord’s Select Committee’s call for evidence
beyond our influence on specific techniques to our developments, most on offsite construction, and teamed up with
projects. We have formed ground- recently through our membership with the the Department of Health and Social Care
MTC. This collaboration is helping us to forge (DHSC) to respond to the IPA's proposal for a
breaking collaborations with the
new pathways through the integration of New Approach to Building - Platform Design
Infrastructure Industry Innovation manufacturing processes into construction for Manufacture and Assembly; sharing our
Platform (I3P), the Manufacturing and enabling us to develop prototypes of views in the hope that our insights and
Technology Centre (MTC), Buildoffsite, new offsite components and materials. examples of best practice may help to
Constructing Excellence, ProCure22 accelerate the 'offsite revolution'.
We have also been working with CIRIA and
and Construction Industry Research the University of Cambridge to quantify the
and Information Association (CIRIA), to benefits of offsite manufacture, proving its
name a few, building partnerships with worth with quantifiable information,
a network of organisations to influence collecting data in a format that will enable
Award-winning
positive change in offsite and modern comparison and identifying a uniform
methods of construction. measure for determining productivity.
Our people, our projects, our approach
Our leading approach to offsite and
modern methods of construction has
most recently been recognised at the
2019 Offsite Awards, where Kier was
announced 'Offsite Pioneer of the Year'.
Each year, our projects and people are
consistently recognised at these awards,
which promote outstanding examples of
prefabrication and factory-based methods,
products and systems.
By positively promoting our success we hope
to encourage others within the industry to
Equipping our supply chain for the future implement offsite construction and
habitually consider it as the preferred choice
compared with a traditional solution.
Recognising the challenges specialist By supporting our suppliers to reach offsite
contractors and SMEs will face in order competency, we are helping to remove
to adapt to new ways of working, we barriers they may face in bidding for future
are supporting our supply chain to raise work, as the industry develops over the
coming years.
their level of offsite understanding and
capability. Increasing numbers of our supply chain are
now equipped to work towards offsite
The extent of specialist supply chain input techniques. They understand how offsite
required at Project Capella kick-started our changes the design and procurement
initiative to upskill our supply chain via the process and are not disadvantaged when it
Offsite Management School, which aims to comes to securing work. We hope that our
ensure all suppliers are equipped to deliver legacy will be that gradually the pool of
the government’s 2025 construction ‘specialist contractors’ within the industry
strategy through modern methods of becomes a much more diverse pool of
construction. contractors.
12 13The time and design cost saved from a
Platform design
streamlined design process can be used in
a number of beneficial ways, from solving
site-specific problems to refining designs to
drive further efficiency and more general
research and development.
Design powered by digital engineering Over time, the power of AI and machine
learning could examine a number of areas,
At the moment conversations around including assembly procedures and in-use
offsite focus on the on-site savings to statistics to drive even greater efficiencies.
resources, personnel, waste and time. Approved
Next generation Building Management
Standards products and Customer Physical
Whilst the figures are not to be dismissed, Systems play a pivotal role in building’s
and guidance components choice constraints
they make up only a fraction of a effective functioning. Efficiencies will be
construction cycle. What if design powered gained through real-time optimisation of the
by digital engineering could reduce building system, using connected devices to
monitor movement and providing a
preconstruction to a matter of weeks?
predictive and proactive level of
The industry is naturally moving toward autonomous capability. For those using the
construction-focussed offsite efficiencies. The building, meeting room booking becomes
potential gains from investing in design could be seamless, lighting and heating systems
huge - driving productivity by reducing our spend adapt to conditions and occupancy levels.
on repeat design and reallocated to continual This increased control given to end-users by
improvement. .............................................. next generation BMS systems gives a much
greater say in the functioning of the
Buildings are designed using rules - space per
building, lessening the need for absolute
occupant, load tolerances, component size etc.
control over the building’s make-up.
RULE-SET
There is rich data on the way buildings are most
effectively used; such as school classroom A next generation BMS combined with
sizes, hospital ward layouts etc. All of these driven data-driven platform design will give clients
inputs influence design, but why not use
technology to have them determine design? design control over elements that are important to
them within a framework of options that are
efficient and cost-effective to build.
We already know how much space is needed,
what the best in class materials to use are, how
to put them together and how long it will take.
We can calculate how that changes between, for
example, a 200 pupil school or a 20 ward
hospital.
So, why not input requirements and have fully Platform design in healthcare
populated design automatically generated?
The time and design cost saved can be put to Kier has been working to develop a
use solving site-specific problems, R&D and platform approach to healthcare
refining designs to drive further efficiency. assets as part of our ongoing
Moreover, the power of artificial intelligence (AI) collaboration with the Department of
and machine learning could bring even greater Health and Social Care on the
gains over time. Instant BIM Level 3 model Procure22 framework.
methodology, (As built We are also working with the
Platform (or rule set driven) design doesn’t limit programme and digital model)
choice but controls choice, focussing on Department for Education, Core
commercial data Innovation Hub and the Infrastructure
customised spaces in the same way as choosing
options for a car or designing a kitchen. Projects Authority to create a common
platform approach to superstructure,
populated with standard components
and assemblies drawn from a library of
repeatable rooms.
By combining workstreams across
organisations, we aim to bring
Traditional design and evidence-based, proven elements
construction together in support of their use. This
Design (6 months) Construction (20 months)
will support better healthcare
Platform design Saving Saving outcomes, as well as address wider
social, economic and environmental
combined with offsite
benefits across the public estate.
manufacture Design (1 month) Construction (12 months)
14 15Our experience 16 17
Kier’s evolution of MMC: our journey to The Choice Factory
Manufacturing Facilities
A variety of purpose-made Dinorwig Pumped Storage
Bath Bridge Wedge House
equipment, switch panels and plant Europe’s largest pumped storage
In 1928, Danish engineers Olaf London Zoo Penguin Pool was designed and manufactured at 600 brick-faced precast facade
scheme circulates 6.6 million m3 of water Maentrwog Dam
Kier and Jorgen Lotz formed J our Harlow factory. Colchester Hospital panels, weighing 4,200 tonnes,
One of the first buildings to over 5 hours between interconnected
Lotz and Kier. Their first project First new dam built in Britain for a were installed in just 17 weeks
demonstrate the expressive and high and low-level reservoirs to smooth The use of 148 steel-framed
was a bridge in Bath, which is generation; 40m high and 120m long. by a handful of operatives.
structural potential of reinforced fluctuations in demand. modules reduced the overall
still in service today.
concrete. programme by six months.
Project Capella Reading Gateway
80% of the frame and façade Steel frame panels,
was built offsite as high quality pre-assembled with interior
BP House precast modules. weatherproof board, were
1920s Coppermill Works New offices in Harlow built on a used for this new 120-bed
40-acre site with extensive use Premier Inn.
For the Coppermill Works of precast concrete columns.
contract in North East London
more than 15,000ft steel
linings were prefabricated here.
2010s Mersey Gateway
Gatwick Airport North
1930s
Highpoint I and II Extensive use of precast, high-
The repetitive nature of
Terminal strength concrete, permitting rapid
One of the first examples of ‘box- operations enabled the
construction cycles and resulting
frame’ construction in Britain and training of local labour that Enabled Gatwick to move into M6 Smart Motorways
in low maintenance and durable
widely recognised as one of the had no previous experience the position of the world’s
finest residential buildings of its time. of tunnelling operations second largest airport. One Snowhill Southend Pier structures. (J16-19)
and little experience of civil Features a dramatic Cultural Centre Use of standard, repeatable
engineering work. inclined unitised glazing processes and solutions to enable
Tower Hill A 170 tonne steel frame
Grafham Water Station 1990s system, overhanging the
viaduct by four metres.
prefabricated building,
barged to the end of the
a rapid and efficient delivery.
The biggest man-made A new three-track pier and lifted into position.
stretch of water in England layout underground Warangoi Hydroelectric
Trans-Iranian Railway
- 14,000 million gallons - station at Tower Hill. Won as a result of Kier’s alternative
Throughout the 1930s Kier all held in place by an 80ft design for a shield-driven, boltless,
expanded overseas. This high, 1-mile long dam. segmentally lined tunnel. Lakeside
contract formed our first joint HMP High Down
Shopping Centre Berkeley Green
venture with Edmund Nuttall A precast panelised system was
(now BAM Group). One of the largest retail used for the wall panels with The first UK application of
Medway Bridge destinations in a single glazing and security grilles cast in. hardwood LVL technology, reducing
Holly Frindle House location in Europe. The quality of finish meant it could unit sections for a more efficient
A new key piece of and cost-effective prefabricated
Experimental use of the M2 motorway,
be painted without plastering. HMP Oakwood
timber structure.
Finsbury Health Centre ‘frame and fill’ with including a footpath 1,600 cells featuring precast
cantilevered façade. and refurbishment to Bamford Water Treatment concrete panels, risers and roof
Provided healthcare free at the original bridge. Hilton Hotel Liverpool cassettes, totalling over 15,000
the point of use; a decade Substantial extension to the
existing water treatment works To maximise internal space, a individual prefabricated elements.
before the NHS was formed.
for Derwent Valley Water Board. white-finished precast concrete
Designed by Berthold Lubetkin
Mulberry Harbour self-supporting solid gable end
and Tecton architects. Ironbridge Cooling
Itchen Bridge frame was devised.
As part of the war effort two Towers
prefabricated harbours were The iconic pink was achieved For this project we designed
1970s
taken in sections across the an innovative method of
by adding pre-packed bags of Sizewell Nuclear Power
Channel with the invading army powder into the concrete mix. launching the central precast
and assembled off Omaha Beach. concrete beams.
Station Hampton by Hilton
3ft high rings of concrete
were poured per day. Metropole Hotel Birmingham 4,000-tonne cooling water tunnel 201-bed hotel utilising Trago Mills
elements were precast at Teesside, shipping containers as The construction of a retail and
Introduced quick, economical
launched and towed to Sizewell, then DTTCP Lyneham modular bedrooms, produced leisure store on the outskirts of
methods of construction including
lowered into a pre-dredged trench. in a factory in China before Merthyr Tydfil, featuring modular
bathroom pods, pre-assembled in St John Fisher Secondary 90% pre-fitted modular single living
pairs as complete modules. being shipped to Bristol. cladding kits for 17 iconic
School accommodation for trainees. The
Spa Green Estate
1940s solution comprised self-supporting towers, factory-fabricated offsite
A radical plan for Kier’s first ever involvement with lightweight steel frame modules. in fully finished condition.
CLT, and the largest CLT panel Crossrail
post-war social
building in the country at the Precast segments were manufactured
regeneration, designed
1950s
time of construction. Hinkley Point C at our Old Oak Common facility and
by Berthold Lubetkin
loaded onto the mobile underground
and Tecton architects. 10,000 linear meters of
factory. The segments formed rings to
precast concrete culverts used
Lecaplan System Built Channel Tunnel Rail Link line the tunnels.
Owen Falls Dam to divert the Holbrook stream,
A major hydro-electric
Houses 2,000-tonne steel bridge (including allowing for easier logistics.
scheme in Uganda across A system of industrialised housing acoustic cladding) was assembled
the White Nile, opened by based on large lightweight Leca off-line and launched over King’s
the Queen in 1954. precast panels, introduced by Kier Cross main railway lines during a
in response to the Government’s 55-hour possession.
call to meet the pace of housing
demand.
Michael Sobell Sports Confidential HQ
Concrete Train Hong Kong Trial Tunnels South Hook LNG Terminal
Centre Utilises an innovative air
A method of laying concrete for 1960s A major development in sports
First tunnelling project for the Hong
Kong underground railway system.
The biggest marine project in
Europe. 440 concrete units, up to
conditioning system, using the
Sainsbury Wellcome
roads and runways, including lake to assist the building’s
centre design. Built over 40 years Featuring the largest compressed 50 tonnes, were cast up-river and Centre
Heathrow Airport where 75 acres of cooling system by regulating the
ago and still provides first class air installation in the world. shipped to site.
concrete was laid using the machine. Hackney Power Station temperature. Vertical risers, plant rooms and
facilities for a variety of sports.
horizontal service runs were
Turbine House, Precipitator House,
prefabricated offsite, as well as a
Coaling Tower, Boiler House, a 200ft
Wellcome Wing bespoke unitised glass facade.
high chimney, and precast bridge with
segments assembled at certain hours A technically challenging new
2000s
to prevent obstruction to canal traffic. extension to the Science Museum in
London, suspending three tray-like
exhibition floors using steel plates
built into concrete columns.
18 19Project
The results
The challenge
The early decision to incorporate
The project is located within 250 metres of glazing into the precast panels negated
Southwark Underground station, with many the need for scaffolding, significantly
bus routes serving Blackfriars Road and the reducing work at height over a public
immediate area. The main elevation faces a footpath.
busy main road and cycle superhighway, on The fast installation method allowed
an extremely restricted footprint site just one person to fix each unit to the
adjacent to occupied buildings, including a structure, vastly reducing all associated
church. Operation of superhighway could not travel implications for secondary
be suspended during the works and we were materials and labour including far
required ensure minimal impact on bus fewer installers, no mortar deliveries or
services and the community. Successfully mixing on site, no blockwork and no
managing logistics was therefore crucial to scaffolding. Site waste and dust
our strategy to maintain programme and produced by on-site cutting and
limit disruption. cleaning was eliminated, as well as any
delays due to weather conditions.
The solution
Offsite manufacture also removed the
The structure of the building was specifically tolerances of traditional brickwork,
designed to accommodate brick-faced ensuring a consistent and exceptionally
precast concrete façade panels. Around 600 high-quality finish.
panels, each weighing seven tonnes, were
fixed directly to the frame; installed complete
with factory-fitted windows and buff and grey
simulated handmade brick slips.
The Hoxton, Southwark
An exceptionally high quality precast façade
The Hoxton in Southwark is a striking new mixed-use hotel and office development
that maximises client value, having navigated the considerable logistical
challenges of a central London site to create a spectacular building that visually
showcases the potential of offsite construction. The main driver for the selection of
an offsite manufactured facade was a reduced programme period and lack of
space on the severely restricted site.
20 21Project
Kier utilised a Light Gauge Steel (LGS)
Windlesham School
construction system as it lent itself perfectly
to the rapid programme and the consistent,
modular nature of student residential
building design. It also permitted a variance
and diversity to façade treatments. The LGS
frame ensured an economic and sustainable Stunning cross laminated timber and glulam pool
solution; minimising waste and cutting
carbon emissions through reduced
deliveries. Set in 65 acres within the beautiful South Downs National Park, this outstanding
new build sports centre comprises a new indoor swimming pool (25m six-lane)
769 bathrooms were also manufactured
with spectator viewing galleries, changing facilities and a sports hall
offsite as Glass Reinforced Plastic (GRP)
pods, giving a one-piece seamless room that
accommodating four indoor playing courts.
is leak-free, strong, durable and low
maintenance. Designed to complement the historic The light-filled pool features warm glulam "The finished build is fantastic. It
architecture of the Windlesham House beams, a cross-laminated timber roof and
The steel frame solution utilised full BIM really has surpassed all my
School estate, the exterior features a green colourful lane dividers that represent the
Level 2 capabilities, including a complete 3D
roof, PV panels and a precast flint wall; a school colours, providing children with a expectations and is going to
model of each building to allow full
traditional feature of the estate, welcoming, safe and fun new facility. transform the lives of many
coordination with other designs, such as generations of pupils and staff."
manufactured offsite in order to intelligently
façades and M&E installations.
minimise the impact of the new building. Richard Foster, Headteacher, Windlesham School
Northampton
Waterside Student
Residences
Versatile pre-assembled steel framing system
Part of the University of Northampton’s campus relocation programme, the project
provides circa 1000 student bedrooms across two distinctly different building
types; a more traditional cluster flat arrangement coupled with an array of
townhouses.
22 23Project
"A genuine example of real
supply chain collaboration
delivering measurable benefits
– a template for the future of our
industry."
Construction News Awards Judges' comment, made when
Project Capella
awarding Kier the Supply Chain Excellence award in
recognition to our leading approach demonstrated at
Project Capella
From blank piece of paper to an enclosed
building in 24 months
Project Capella is a biomedical research laboratory for the University of
Cambridge, located within the Cambridge Biomedical Campus where £600m of
research buildings are being constructed concurrently.
The challenge
Project Capella is located within the
Cambridge Biomedical Campus, where £1bn
of buildings are being constructed
concurrently. Due to the overheated local
market, creative thinking was required to
ensure construction could be undertaken at
the fast-track pace required by our client. To
limit on-site labour and mitigate local
resource and material availability, we
aspired to maximise offsite construction.
Through early engagement across our supply
chain we were able ensure design realised
the aspiration to prefabricate as much of the
superstructure as practically possible and
de-risk the project.
As a research laboratory, the building has
stringent vibration criteria, far in excess of
typical requirements. This is usually
achieved via an insitu-poured concrete
frame, however, local concrete demand was
identified as a risk. Working closely with our
supply chain, we developed a precast
concrete/hybrid frame that could meet the
challenging vibration requirements.
The results
The solution
The use of pre-glazed precast façade
panels meant the building was
Kier was appointed during RIBA Stage 1, watertight significantly earlier, which is
which meant we were able to lead and key in a laboratory building, enabling
influence design decisions early, resulting in early MEP installation. Through
a shift from traditional construction towards exhaustive co-ordination and planning,
maximised prefabrication. 80% of the frame deliveries were reduced by 750 from
and façade was built offsite as high quality initial estimates and operative hours
precast modules, and much of the MEP was halved. Kier also oversaw more than
factory-made away from site. The complex 500,000 hours without a single
frame and façade comprised 3927 RIDDOR.
elements. Panels were delivered
immediately before installation, resulting in Early engagement and open
construction being 20-weeks faster. collaboration between Kier, our clients
and our supply chain allowed for a
more open process that drove out
unnecessarily risk allowances and
promoted innovation, giving suppliers
the opportunity to work together at a
time when their input could have the
greatest impact.
24 25Project
By value, offsite technology accounts for a
FA Parklife
quarter of the project’s build cost. The
façade was made entirely offsite, which
resulted in a more efficient, safe and speedy
construction process. It provides the same
performance as a traditional clad building
but was installed with a greater degree of Seamlessly integrated modular football facilities
accuracy, quicker and using 40% fewer staff.
Other offsite elements included precast Kier successfully handed over a programme of four projects to Liverpool City
concrete columns, MEPH elements included Council, providing brand new facilities at key grassroots footballing locations
chilled beams and rooftop plant rooms, as
across the city. Each project was delivered on time, to budget and created an
well as 96 bathroom pods, which were
cost-effective and efficient to install. extensive amount of social value for the local area.
Modern methods of construction minimised
The aim of the programme was to create a Each of the FA Parklife buildings is "Using varying techniques and
the possibility of accidents, and the entire
sustainable model for football facilities completely bespoke and can be demounted
project, over 670,000 hours, was completed material enhancements has
based around artificial grass pitches on hub and moved to a new location, making them
RIDDOR free.
sites. Two of the sites involved the 100% re-usable. 90% of the offsite supply allowed an offsite solution, not
construction of six modular team changing chain were located within a 30-mile radius of only to provide buildings at an
"A number of things in this project facilities and fitness centres. The remaining the modular manufacturing facility and, accelerated rate, but also
helped in terms of innovation. two sites benefit from the addition of where possible, all materials were bought in allowing the Kier team to develop
Three that come to my mind are
modular fitness centres to their existing at size, reducing waste. Timber, steel and and deliver a fast track solution
the façade and early
traditionally built pavilions. plasterboard waste was also 100% recycled for all aspects of the works."
by our supplier.
subcontractor engagement, Christopher Turner, Commercial Director, Integra Buildings Limited
[and] that we had offsite
manufactured toilet pods, which
allowed our M&E services to
progress much more quickly
through the building." “It has been a pleasure to work with Kier
Sam Williams, Project Manager, Argent since the preconstruction period to deliver
the four projects to meet our deadlines. The
programme of work had its challenges, but
it was the working together as one large
team, regardless of organisations, that
ensured the success of such a large capital
project with numerous stakeholder groups."
Mike Kearney, Head of Sports and Recreation, Liverpool City Council
R7, King's Cross
25% of the project constructed offsite
Delivered on time and to budget, R7 is a striking building that incorporates offsite
technology effectively and efficiently. The building benefits from an open minded,
holistic approach to decision-making, ensuring each construction choice was made
with all benefits and pitfalls considered.
26 27The challenge
At Wexham Park Hospital, Kier was
contracted to provide a new Emergency
Department and Assessment Centre. The
new development was designed to replace
and consolidate existing emergency facilities
under a single roof, aiming to reduce the
length of stay and number of long stay
admissions, and eliminating the need to
move patients long distances across the
hospital site.
The solution
The new building includes a modern
emergency department, supported by
medical and surgical assessment units and
staff accommodation across four floors,
providing comprehensive patient care within
one building.
The building incorporates a wide range of
services, including 36 individual majors
rooms, imaging and diagnostic suites, eight
resuscitation cubicles, a 34-bed combined
assessment and ambulatory care centre, as
well as separate paediatrics and minor
injuries units.
Whilst the frame was being built, 164
mechanical, electrical and plumbing service
modules were manufactured offsite, the
equivalent length of nine football pitches.
This enabled a fast-track installation, with
four modules being fixed each day.
ProCure22
The use of standardised components and
repeatable rooms also allowed streamlined
decision-making, saving hours of
consultation time.
Repeatable rooms and improved efficiencies
The Repeatable Rooms and Standardised Components initiative is part of the The results
Department of Health’s Cost Reduction Programme for NHS schemes. As one of
six Principal Supply Chain Partners on the framework, Kier collaboratively worked Wexham Park Hospital was delivered
to determine best design practice for a number of rooms. Within the space of 10 early, on budget and to high quality
months, we developed evidence-based healthcare designs to improve patient standards, with no unplanned service
outcomes, whilst delivering capital construction cost reductions. The ProCure21+ interruptions across all 250,000 hours
initiative won Supply Chain Excellence at the 2016 Construction News Awards. worked.
Optimum flows were achieved whereby
"Repeatable rooms represent best practice in design. We were looking no one needs to go back to the same
not only for cost efficiency, but also for efficiency in operation and place, instead, moving through the
improvements in patient safety. One of the benefits of a repeated building as treatment is provided. This
room layout is that staff become familiar with the layouts and has improved efficiency and is providing
equipment within a room, and that helps them to provide good quality a much more stress-free environment
for patients, a key concern for the
care for patients."
Emergency Department clinical teams.
James Hayward, Capital and Infrastructure Programme Director, York Teaching Hospital NHS Foundation Trust
The use of offsite techniques reduced
the duration of the first-fix programme
by 30% and the amount of labour
required on site by 50%, limiting the
impact of construction activities on the
live hospital site.
28 29Project
The new BREEAM ‘Excellent’ building houses
HMP Oakwood
extensive flexible laboratory and write-up
spaces, a lecture theatre, offices, meeting
rooms and seminar facilities over six storeys
above ground and a two-storey basement.
Vertical risers, plant rooms and horizontal
service runs were prefabricated offsite
Landmark project featuring almost 20,000
and delivered just prior to installation. In prefabricated elements
addition, a bespoke unitised façade was
created using established materials (low iron
cast glass) in an unusual way to create a Handed over three months early, Kier maximised the use of pre-fabrication at HMP
translucent and high performance envelope. Oakwood. It was one of the first projects to use a range of different manufacturers
and suppliers, including six leading UK pre-casters. The project won the British
Offsite building services assembly reduced
the hours spent on site, significantly reduced
Precast Innovation Award in 2011.
waste, improved health and safety and
meant all components could be quality HMP Oakwood is a self-contained Category B Large factory-produced precast concrete "What you’ve [Kier] done and your
checked before delivery. The project was prison establishment located adjacent to panels form the majority of the internal
vision for showing public sector
delivered without any accidents reported HMP Brinsford Young Offender’s Institute structure, the façade system and the stair
across all 1.8 million hours worked. and HMP Featherstone, Wolverhampton. The elements for the prison buildings. In total, as a world-leading class deliverer
scheme included three house blocks and 14 almost 20,000 prefabricated individual of projects has come to fruition, I
ancillary buildings, providing accommodation elements were used on the project, including believe, through Oakwood."
"We are delighted with the units consisting of over 1,600 cells. precast concrete panels, risers and roof Terry Stocks, Ministry of Justice
completed Sainsbury Wellcome cassettes.
Centre. The Kier team has worked
collaboratively with us to exceed
our requirements for quality,
performance, cost certainty,
health and safety, good
neighbourly behaviour and
security... The strong
understanding of our design
vision is clearly exhibited in the
final building."
Stuart A Johnson, Strategic Project Manager
Sainsbury
Wellcome Centre
A stunning cast glass façade and modular M&E
Shortlisted for Best Use of MEP Prefabrication at the 2016 Offsite Awards,
Sainsbury Wellcome Centre is a landmark research centre for University College
London that features factory-made elements to an exceptionally high quality.
30 31“At Highways England we recognise the
productivity and efficiency challenges that
the UK construction industry is facing. In
recent years we have encouraged more
computer-led design, automation, and The results
pre-assembly across all of our construction
M6 Smart Motorways
activities... We will adopt ever increasing The one-team approach of all main
levels of automation and offsite construction contractors across the programme is
on road improvement schemes and smart simplifying this complex project for our
client. Highways England can deal with
motorways in our next five year road
an integrated team using the same
Maximising efficiencies across a programme investment programme.” catalogue of products to deliver a
Jim O’Sullivan, Chief Executive, Highways England consistent service, which is providing
procurement and programme savings.
Working in partnership with Highways England and other main contractors on our
M6 Smart Motorways upgrade scheme, we are maximising the use of repeatable Managed under a collaboration
processes and solutions; increasing economies of scale in procurement to deliver agreement, Smart Motorways delivery
efficiencies. Standard products are designed collaboratively once, then procured partners can share knowledge and
best practice. Drawings are repeatedly
and delivered multiple times.
shared, improving with every iteration.
This rapid and efficient way of reviewing
and approving design gives Highways
The challenge England sight of designs in advance of
formal submissions, speeding up the
Working safely and minimising disruption to process of timely approvals and
road users are key priorities for the M6 optimising the design.
Smart Motorways scheme. Works are
carefully planned around key events,
holidays and traffic management for
neighbouring network schemes. Our project
teams are required to work within narrow
lanes with restrictive access and egress
points, whilst maintaining live lanes of traffic
for the 120,000 road users.
The solution
At our M6 junction 16-19 upgrade, a
collaborative culture was enhanced through
co-location with the design team,
construction team and client; c200 staff. A
20-mile long safety barrier was installed
using 5,000 precast units, each weighing
four tonnes, and steel gantries fabricated
offsite to support 258 signs, 70 cameras
and speed control lights. Offsite
manufacture of these elements has brought
increased safety benefits to operatives and
the public, and reduced disruption through
fewer road closures.
Throughout the early stages of the M6
J13-15 scheme we considered several
options for offsite manufacture. Taking
lessons learnt with risk, quality and
programme constraints associated with
insitu casting of drains, we collaborated
early with our specialist precast contractor to
develop a precast AquaSlot drain. This
innovative product has been designed to suit
the requirements of mass production for
Smart Motorways and can be laid in most
weather conditions, improving programme
certainty and providing a fast installation.
32 33Project
The challenge The solution
DTTCP Lyneham This major project involved the construction
and refurbishment of 83 assets, as well as a
site-wide upgrade of the existing utilities
The team selected a modular approach to
provide single living accommodation for
trainees, with a total of 1,600 new bedrooms
Modular accommodation network across a 1,200 acre site, within a
tight 18-month construction programme. At
across 20 buildings, plus communal rooms
and entrance foyers. The solution comprised
peak, there were 1,400 operatives overseen self-supporting lightweight steel frame
DTTCP Lyneham, delivered through a 50 / 50 joint venture between Kier and by 120 management staff on site, all modules, designed to carry and transfer
Balfour Beatty under the combined name of Hercules, transformed a former RAF required to complete security vetting vertical loads.
processes for the secure site.
airbase into a new Armed Forces training facility for the Defence Infrastructure Specified to the equivalent standard of a
Organisation. The scheme delivered single living accommodation for more than Logistics, traffic management and reducing three-star hotel, each new individual
1,100 trainees, purpose-built teaching facilities and outdoor training areas. the amount of labour required on site was bedroom unit comprised a wardrobe, desk,
therefore crucial for the efficient and safe lighting and power fittings, en-suite shower
functioning of the development. Weekly room and curtains. Each room was 90%
This project is a fantastic example of how we are supporting our logistics meetings were held to establish the pre-fitted, in a low-risk and controlled
armed forces by providing the right facilities in the right place to meet following week’s traffic management plan. environment, before it arrived on site.
their needs. The close working relationships and team effort between The meetings were attended by our safety
3D modelling was used to create structural
all those involved within this project has resulted in the early handover department and all subcontractors, peaking
details for factory manufacture and to
of facilities. at around 30 subcontractors, from utilities
co-ordinate with the M&E design.
and cable companies to our modular unit
Vicky Bodman, DIO Lead Project Manager
supplier.
The results
Modular construction commenced two
months in advance of modules being
delivered to site and the twelve
accommodation buildings were handed
over on time, ahead of the autumn
intake of trainees.
Due to the success of the project, Kier
has since been contracted to provide a
further 296 modular rooms over five
blocks at Lyneham, due for completion
in 2020.
34 35Kier Group
Tempsford Hall
Sandy
Bedfordshire
SG19 2BD
For more information on offsite solutions
at Kier please contact:
E: Elizabeth.Biggins@kier.co.uk
T: 07856 003675
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