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Construction's Digital Manufacturing Revolution - YouTube
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the world we build impacts almost every
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human being on this planet
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from the environments that we call home
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to the way we travel generates our
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energy drive our economies and shape our
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children it is the construction sector
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that underpins the direction of our
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societies but despite its fundamental
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impact on our way of life our approach
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to construction has changed little over
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the ages and we still use many of the
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same techniques and materials to build
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prototype structures in volatile outdoor
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environments
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now as our planet experiences
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unprecedented change the sector is
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embracing rapid advances in digital
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technologies and making a bold shift
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towards the world of manufacturing
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merging the two to usher in a new door
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[Music]
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for centuries the way we construct our
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world has remained largely unchanged
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still using many of the same materials
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and processes each project that the
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construction sector undertakes requires
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the delivery of a unique product in a
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unique outdoor location
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moving works away from the challenges of
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each site and into controlled conditions
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offers many benefits
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economies of scale can be achieved
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through automated production lines
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productivity can be significantly
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improved and quality can be ensured such
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an approach also reduces the amount of
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time that a project is on-site for
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helping to lower costs negate
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site-specific challenges and to minimize
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disruption
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the extent to which construction works
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are taken away from their final sites
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varies hugely
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while volumetric solutions create entire
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enclosed spaces remotely and then
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deliver those to site for installation
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non volumetric systems are large
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elements of a building or structure that
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are prefabricated before being brought
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to site on a more granular level
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component based approaches and platform
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systems creates a kit of paths and draw
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from a series of predetermined items
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that are consistent across a number of
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projects each of these off-site
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construction approaches offer different
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benefits and each has its advantages
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depending on the type of project being
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built however non volumetric and
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component based approaches can retain
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the benefits of off-site production
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while offering the adaptability needed
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across the many different types of sites
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that the construction industry contends
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with
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but despite the seemingly compelling
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benefits over several decades the
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concept of off-site construction has
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struggles to find traction now with many
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countries facing rising populations
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housing crises and a lack of skilled
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people coming into their construction
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workforces and with technology coming to
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the fore there is renewed excitement in
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the concepts it is technology in
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particular that is helping to make the
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step change and overcome the
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long-established barriers the rise of
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automation is hugely increasing
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productivity on production lines while
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digital design information is helping to
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streamline processes and increase
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accuracy it is in this way that the
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concept of off-site construction is
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rapidly evolving into offsites
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manufacturing a shift that sees the
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construction process move much closer to
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the approaches of the manufacturing
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sector and the techniques it has honed
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that shift can be clearly witnessed at
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the UK's explore industrial park
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conceived and owned by Laing O'Rourke a
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global general contractor with some
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13,000 staff and an 8 billion pound
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pipeline the vast factory is the most
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automated concrete product facility in
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Europe
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since opening in 2009 Explorer has
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manufactured concrete elements for some
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of the UK's most impressive projects
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including London's 48 storied Leadenhall
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skyscraper and terminal 2 at Heathrow
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Airport
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Explorer industry our Park is one of the
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most advanced precast manufacturing
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facilities in Europe it allows the lung
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our crew to control its own supply chain
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to a large extent we can react quite
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quickly to requirements on-site as a
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result of that with the IP Allegra has
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managed to move 70% of its on-site
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manufacture to of an off-site means and
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that's brought a 60% increase in
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productivity and a 30% increase in
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accuracy to the delivery schedule
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what sets us apart from other precast
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manufacturers is our use of automation
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through machinery on the factory floor
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also software tools that we use in we do
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a lot of engineering of our processes to
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ensure it as as efficient as possible
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automation is very much a part of that
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paradigm shift and having the right
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automation can eliminate most of the
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issues a typical design process would
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encounter so your human area uncertainty
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your factor of risk everything else is
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just eliminated when you have a reliable
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precise system doing it for you
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throughout the last 10 years
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explore Industrial Park has continually
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evolved and innovated embracing
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automation and digital technologies as
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they have matured
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repetition honed processes quality
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control and a consistent flow of work
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are all key to the facility's success in
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this context it is critical that the
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design information shared with the
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production teams that is used to cast
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and form concrete components is accurate
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for major projects like Manchester
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airports transformation program and
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Liverpool's new specialist cancer
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hospital both of which are currently
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moving through the factory the
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importance of accurate digital data
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could not be more acute
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errors in production can slow the
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overall progress of projects affect
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other activities out on the construction
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sites and mess up the factories work
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schedule costing time and money because
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we're the point where things are cast in
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concrete as they would say it's it's
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quite important that we assess every
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single facet of the design from a
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project landing and explore we would
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meet with a site team the clients
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architects and structural engineering
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consultants is as well as interfacing
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disciplines we'd go through the product
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set look for similarities between
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different component types and we try to
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rationalize them this allows us to
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achieve a level of standardization
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across a project we take the concept
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that the architects and the engineers
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want to enforce and bring that to
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reality so we have to think about how
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manufacturable it is how handleable it
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is and how viable it is for the build
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where typical manufacturer would
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generally produce one product type in
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one preakness Factory this precast
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Factory we produce multiple so we can
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supply all the precast on the project
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that allows a certain level of
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coordination between the different
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product sets other things that set us
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apart are the complexity of the products
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that we're willing to manufacture
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traditionally precast concrete is it's
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very simple geometries we do a lot of
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architectural product here that explore
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that might not find elsewhere
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from the outset of a projects Laing
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O'Rourke steams consider which elements
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could be fabricated away from the
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construction site
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working within the broad parameters of
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what the factory can achieve they then
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developed detailed design information
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models to inform both the construction
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and operation process and the
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manufacturing of components
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to ensure the accuracy of their digital
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information the team use Sallee Bri
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office to validate its contents
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pulling information from various
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different members of the design team
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into a single combined or federated
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information model in Sallee Bree the
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tool can then be used to check the
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quality of that data communicate any
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issues enable quantity takeoff and
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classify components
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with their desired information quality
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checks the team then issued digital
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production information directly to the
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factory floor where the process of
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component manufacture begins
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from the cutting and fabrication of
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steel reinforcement cages including
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placement of the ties to the
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distribution of concrete across the
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factory the pouring of that concrete and
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the process of curing it Laing O'Rourke
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manufacturing process is highly
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automated helping projects delivered
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through Explorer to take significant
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strides in productivity
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once produced the building elements are
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loaded onto vehicles taking into account
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the order that they will need to be
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unloaded in and are transported to their
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sites
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those on the ground in the project's
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location are able to seamlessly engage
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with and see the data about their scheme
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through tools like syllabary anywhere
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which enables access by any member of a
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project team wherever they may be and
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syllabary site specifically tailored to
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those working in the field the
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geographic positioning of Explorer in
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the very center of the UK is deliberate
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and the factory has created components
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for sites in both the South of England
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and in Scotland
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from the outset of the design process
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right through manufacturing to the
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delivery and installation of components
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on-site and the operation of the built
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asset afterwards
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the entire process is informed by
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digital data
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the success of such projects is
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therefore dependent on the quality of
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the data used and the idea of not
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quality checking or validating it seems
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very risky if something is inaccurate it
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cannot only be at the detriment of your
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product and your quality in your safety
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but it's immediately visible in your
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coordination checks I mean as a species
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were quite a visual species so now that
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we're doing everything in 3d it needs to
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be spot-on or you will know about it one
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of the things that we use suite before
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primarily is checking the quality of the
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incoming information so cria had tours
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receiving information as well we provide
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the consulting engineers or architects
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with a library of standard objects
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produce a bit object library we then
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pass that back to the consulting
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engineers they populate their model and
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then provide the site information we'd
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also do checks between the different
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precursor elements for construction
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joints to make sure that as per the
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agreed details you're able to streamline
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the design in the best way possible and
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ensure that everything works before it's
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tangible in any way shape or form so for
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us it's it's very key that we get the
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models and all our theoretical
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understanding of the entire structure
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spot-on before we get anywhere near the
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floor sites once all the issues have
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been closed out then we would transfer
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the model through into our precast RC
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detailing platform we add more detail to
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the models and we'd be adding
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information such as custom fixtures
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reinforcing bars
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basically to get a digital model as to
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what we're trying to produce actually
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our in the factory having a safe system
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that is able to carry out these checks
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for us it eliminates the possibility of
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human error and uncertainty
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giving us a much better outcome in the
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way that the product is built
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information of being right has impacts
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to every single facet of the system
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because if you think about not just the
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safety and the economy of the whole
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thing it's the environmental impact as
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well so to move six tons of concrete all
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the way down to projects let's say in
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London or up in Edinburgh and to have it
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wrong on site waste a lot of time and
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money so it's always key that we
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get it right the first time
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explore industrial park effectively sees
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to of constructions most disruptive new
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innovations come together under one roof
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off sites manufacturing enabled and
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further advanced by digital technology
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run on digital data Laing O'Rourke use
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of Sallee berry during design
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manufacture and final assembly is key to
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ensuring the process runs smoothly
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underpinning the success of countless
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projects indeed as our world becomes
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ever more dependent on data ensuring the
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accuracy of that data so that it can
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serve us in the best ways possible is
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critical it's about having control
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conditions control quality precision all
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of the good things you get from a
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factory setting that you may not ideally
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have the ability to implement on-site
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there's a lot of complexity in their
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systems that we have based at ERP as a
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factory we look at ourselves as any
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other factory the same way an automotive
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factory would look at the way they
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manufacture things while we are indeed
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in a very archaic industry that hasn't
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changed much since Egyptians we're
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trying to be the best we can be by
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looking at industries that are
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fundamentally ahead of the game in the
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way they produce things so we're not
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trying to just be the best construction
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concrete facility we can be we're
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actually trying to be the best
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manufacturing company we can be the
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approach is employed at explore
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industrial park that can offer
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improvements in productivity of sixty
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percent could be the answer to making a
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step change in overall performance
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across the wider industry
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with others now following suit and with
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the trend gaining in momentum across the
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sector worldwide
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combining the power of digital
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technologies with the approaches that
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have made manufacturing so successful is
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seemingly ushering in a digital
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manufacturing revolution in construction
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that could transform the built world
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shaping all of our lives
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you
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