BCA ACADEMY The Basics of Design for Manufacturing and Assembly (DfMA) (2"4 Run) 28 November 2017 School of Graduate Development and Management ‘The Education and Research arm of the Building and Construction AuthorityPlease complete the electronic course evaluation form via the URL https://tinyurl.com/y9ayeo58 or the appended QR code COPYRIGHT: All rights reserved. Audio or visual recording of any lecture, lesson or other teaching session is not permitted. No part of the course materials may be reproduced or made available to third parties in any form or by any means, including photocopying, recording, or by any information storage and retrieval system, without the prior written consent of BCA Academy, Singapore.THE BASICS OF DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA) (2ND RUN) Objective Upon completion of this course, participants will be able to: ‘+ Understand the basic concepts and principles of DIMA; ‘Appreciate design consideration for DIMA; and * Understand benefits and challenges of DMA and how such challenges can be overcome for a successful adoption. Award of Certificate A Certificate of Attendance (COA) will be issued to participants who meet the minimum attendance requirement of 75% Course Topics & Programme Time: Topics & Details | 9:00am | Overview of DIMA to 10:30am What is DIMA “Why DIMA ‘Building a Robust DfMA ecosystem - demand, supply “© DfMA Continuum = single components, integrated components, full integration systems > BIM for DIMA | 4 Procurement framework outline 10:30am | Tea break to {11:00am i 11:00am | Introduction to DMA Technology bed - Introduction to the various DfMA technology along the DIMA an continuum jerations and key factors Learning Points 3:00pm | “ Group Discussion3:00pm | Tea break to 3:30pm © Group sharing 3:30pm | Overview of PPVC Guidebook 5:00pm.DfMA - Changing the Way We Build The Built Environment (BE) Sector and Nation Building Building and Cons SeaportMANPOWER Productive design/technology to manage aging local workforce and tightened foreign workforce ONLY Building and Cons. 18M ~ Building Information Modelling 1yDC - Virtual Design and Construction + Penannl ane at hand BCA Acs We shape 2 sate, high quality, sustainable ond friendly built enviconmentReduce Foreign Workers Dependency - Doing More with Less (i) Dependence on cheap & transient workforce Building and Cons We shape a safe, b EOE Wlash Pea valt lap Ey nating consrvcion SB tery We shape a safe, high quality, sustainable and friendly bult enviroament“VISION OF ROADMAPS Ahighly integrated and technologically advanced built environmentsector that will be led by progressive firms and supported by a skilled and competent workforce by 2020 Pee ay Roadmap | National Productivity Target | 2%=3%anoual row ont 2020 Peer May «PE End-term | | Productivity Growth Target 2014 review =| -1.5% ~2% from 2011 - 2015, 2.5% — 4% from 2016 — 2020 IPE | Mid-term I 2012 review Building and Cons 1st Construction Productivity Roadm: eel uk esld minimum mandatory standards Carrot Q rnd Ona SE | Pe tnt ren a nap TegYear-on-Year Improvement in Site Productivit 0.420 Building Works 0.419 os oat, oa10 = B05 5.400 5 395 ~ 2 % 300 385 9.3g9 0.381 0.380 0375 —_— + ~ y 2009 2010 2011 2012 2013 2014 2015 2016 2.0% 10% cumulative improvement since 2010 Building and Cons We shape » safe, high quality, sustainable 9 e Doing More with Less ipesign for Wea focea Enhance alabraton across ll i for Monica stakeholders slong contruction 3 Assent ‘ale chain Ensuring workers eee 2 “er, Correct ir Adequate sess Sacto Innovation in the way we Design for More Effective Construction Outcomes Building and Construction ‘Authority We shape 2 safe, high quality. sustainable ond@ Technology ea Public Sector Taking The Lead To achieve 25% to 30% productivity improvement from 2010 levels for new projects ¢ EL Naess Hy cheats es Gal Identify pilot projects aero ad emesis "The agencies above constitute >70% of total public Building and Con: sector building and civil engineering works ® recmcoey )[C{ rst setortaling The en | sree soe 8a 2018 7% quality Fee Method (QFM) Price Quality Method (PAM) (procurement of consultancy services) (procurement of construction services) Increment in Productivity wei Increment in Productivity weightage: Bailing andcons 9% - 12% > 20% 3% - 6% > 10% eo shape 9 gate,| @ Technology = > Public Sector Taking The Lead ‘Traditional Construction Off-site Construction On-site Assembly Paretd [1] ICPH Integrated Construction and Prefabrication Hub Building and Con: (2) ppyc Prefinished Prefabricated Volumetric Construction @) Design for Manufacturing & | eee ‘Assembly (DFMA) _Push for Widespread Adoption of DiMA Building and Con We shape a sate, high quality, sustainable and friendly built environment.@® (Design for Manufacturing & Technology ‘Assembly (DMA) Push for Widespread Adoption of D[MA Continuum of Prefabrication & DMA Residential, Healthcare & Hospitality Allbevelopment Types (Hosa Buln = — os Fo chins We anata aoe ope DH technologies by 2020 tea) ie: PED = j ——) c a baling an constrain APE rary We shape a safe, high quality, sustainable ond flenéty but envronment @) Design for Manufacturing & @ recor | ase (ma Raise Minimum Standards of Buildability EN fois ee) | Bune Fly iterated subassemblies = = |e voaretr eve Po0, peers. | je “Advanced prefab systems) (og. Stel Pretnshed wat Prefabricated components. } eo = mere | Building and Construction ‘authority We shape 2 safe, high quality, sustainable ond telendOP ccmoleey =a Strong Incentives Incentivise the Industry to Adopt Technology ¥ copabitty Building Technology Adoption Workforce Training ae if Mechanisation credit (=) {= ee Wt eugene ( Sao Laer, Feces raceth bie! E een oe = ar eeosoerion. funding equipment purchase scenes ae irate = Productivity SraTeas ams ueaa a nae (giecstaemey \ _ roach” Bull Environment Fund (CPCF) [7% sertarin Sonsoratip 7 Improvement | | Breen oo ee | | ‘capabilites by attracting new | ie “and process re-engineering | } “entrants into the industry gs ‘through project co-funding ata | ‘icon epg Bulg and onstrcion Qe natorty (sor We shape 3 sate, igh quality, stainable ond friendly ouMnreyrierenep Value Chain Funding Support for Technology Adoption — PIP Schemes Productivity Improvement Project CHANGING THE WAY WE BUILD Funding cap raised to $10 million for Game-Changing Technologies in 2"! Roadmap loom Ree AC lene aes ed , Tiger eoa tt Breas capacity crane (eeecee))Financial Support for Technology Adoption ethane ekg ua ltire td PIM esi eoaeet Mis ‘Supported (as of end-Dec 2016) > 4,900 applications > ~1,200 firms Total funding committed: ~ $$78 mil i MechC & PIP Schemes y Productivity Improvement Proj Ceo MT Ree sean gee rece tears teen el oi Supported (as of end-Dec 2016) > 1000 applications > 400 firms Total funding committed: ~ 5$150 mil 3D BIM 2D Design & Hardcoy Building and Con Digital Engineering i 4D & 5D BIM SD cwCENTER FOR LEAN AND VIRTUAL CONSTRUCTION Innovate. Integrate . Transform FIRST fully integrated, large-scale eee Fe eat eee eee Virtual Design and Construction: Build twice - first virtual, then real ors Building and Construction We shope 8 he quality, sustainable ond What needs to be done? 1. Rock the Boat 2. Take Calculated Risk 3. Build New Capability 4. Foster Collaborative Approach nang st carries SP erty We shape 2 safe, bigh quelity, sustainable and fviendty built envionment Changing, the Way we Bu aRock the Boat - Government Land Sales (GLS) 2014-2015 2016 Building and Con We shape a safe, iret (Roser) 2017 ‘Commercial Gis te (Reserve site) Rock the Boat - Changing our procurement approach Driving Private Sector Adoption Industrial Government Land Sales (IGLS)_ Increase the Minimum | Minimum Prefabrication Level New* GFA > 500m? |GFA > 25000m? Structural System building works) (in respect of total structural floor area of 25% 40% the building works) Wall System {in respect of total wall length of the 45% 60% Note: new minimum prefabrcatio level with elect frm Apr 2017 Building and ConstructionRock the Boat - Changing our procurement approach Building and Con -— ‘Take Calculated Risk - Innovation comes with problems. How do we overcome them? e.g. Transporting PPVC modules has road safety concerns OTe el sade Mira ap Rens etn daar + Auxiliary police escort requirement was required for heavy vehicles that are 3m wide; 4.5m tall and > 80 tons + Limited the size of PPVC modules and restricted design flexi increased compliance cost LTA has increased max width limit from 3.0 m to 3.4m aaa ace rt Building and ConFoster collaborative approach e.g. Collaborative Virtual Design & Construction (VDC) ~ getting rid of the silo barriers among project parties “Compressed BIM model “ Which may lack key details Building and Con (e.g, annotations) we shape 9 safe, Local Stocktake > Construction industry reliant on low cost labour >» Manpower and technology levels improving with the 1% construction productivity roadmap > Beginning to move towards Df{MA = Improved levels of prefabrication = Initial adoption of game-changing technologies "Integrated Construction & Precast Hubs (ICPHs)Local Stocktake - Barriers Mindset that new technologies are not as reliable Cost premium for new technologies and construction methods Lack of upfront design intent Insufficient time during design phase to explore alternative choices/technologies Lack of coordinated sequencing of construction activities Proposed End-State __ Industry iil "= Core of strong main contractors with integrated supply value chain (e.g. prefab arm, specialist sub-contractors etc.) "= Core of strong prefabricators Y capable of supplying wide range of prefab products ¥ Integrated supply value chain (e.g. specialist, subcontractors) = R&D arms under both main contractors & prefabricatorsProposed End-State ___ Project = On-site: Assembly works > Design that minimizes number of parts/joints > Usage of readily-available prefab components » Laing O’Rourke 70% DfMA = Most of construction works moved off-site > Highly automated prefab facilities > Readily-available BIM design objects = Value chain integration > Collaboration of project team through BIM during upfront design phase " Virtual Design & Construction Simulation Proposed End-State _ Stakeholders] Th] Saar emdestand ents of UA J * Owner demand = primary driver for architects to include DFMA in project design * Understand benefits of DFMA to each stakeholder Educate & advise clients on the use of DFMA in project, Specify DIMA in project design right from beginning = Catalyst for use of DIMA. * Well-verse with availability of prefab/modular technologies & products "Upfront scheduling & cost consideration (Include DfMA into pre-construction planning & bids, = Integrate supply chain * Pursue applied R&DProposed End-State __ Stakeholders] + Make DIMA an integral part of their business * Build up experiences with prefabrication processes to remain = Formalliance / consortium with main contractor / prefabricator + Schedule & cost optimisation * Create BIM objects of prefal + Integrate supply chain + Pursue applied R&D (e.g. process optimisation, finetune design details for ease of manufacturing, reduce components of parts) ted /modular elements Proposed Strategies Mindset Change nana | ptance of prefab techrfilaaaii als : Prefab + Lower Quality Highlight other benefits e.g. reduced dust/noise on- site, shorted construction duration ete which results in less inconvenienceProposed Strategies __ Mindset Change ca Deda Business Case Studies * Identify cost premium for DIMA methods/technologies * Determine payback period to neutralise cost outlay and the benefits that would be reaped thereafter "Articulate to stakeholders the benefits of DfMA Proposed Strategies Supply Chain Upgrading & Integration 000 Collectively raising sub-contractors’ capabilities Weiss vy Integration lain contractors to take the lead in developing relevant training programs (In collaboration with government agencies and relevant associations) ¥ Mentoring programs for sub-contractors (by main contractors)Proposed Strategies Supply Chain Upgrading & Integration (0H © Encourage vertical integration © Mutually-beneficial partnerships i Crna curge ee F score Programme F score Programme improve quality ea uc) Bene esas Sea cs Proposed Strategies Industry Standardization and Specific Trade‘Focusi ill © ‘standardization of specific elements e.g. column/plle sizes (identify elements and features which are most. ‘manpower-intensive on-site) ‘© Development of online shared database (e.g. object library for consultants and builders) © identify and focus on trades that will yield high ‘manpower savings when adopting DIMAProposed Strategies Force upfront collaboration through Constructability Index i.e. Strategies Development & Expansie © Procurement models conducive for early collaboration between consultants, builders and prefabricators (including more time given for developers to sell the units) © covernment mandates to help drive initial demand and accelerate economies of sale © Partnerships with overseas DMA professionals/practitioners to build up knowledge and capabilities © Continue to drive technology adoption through fe mandates/government funding in design (e.g. BIM), off-site prefabrication (e.g. highly automatec ICPHs) and on-site mechanisation (e.g. robotic equipment)Strategies @ Mindset Change _@ Supply Chain Upgrading & Integration’ i/iiiiillt _@¢@ Industry Standardization and: Specific Trade Focus) 6 Force upfront collaboration thro & Constructability Index i.< © _ bevelopment & Expansion of DfIMA\Ecosysteti ill Establishing a Robust DfMA Ecosystem 1. Increase adoption to improve productivity Key Objectives: 2. Reduce cost premium for sustained adoption 3._ Sufficient capacity and capabilities to support adoption cetng sent ed demand Key Strategies! Sieay serearorsetase —C e Sire ona A. Build sustained <—— See SU As dered B_ Resolve regulatory REGULATIONS hurdles C Build supply capacity & Lower Cost for DIMA Technology Adoption ea Building and Construction Bb seonesy we shape 9 sate, high quality, sustainable and friendly but environmentDMCC LC UT Ce ACY)Defining DfMA To achieve Product and Process Optimisation - e ae © Ease of Manufacturing Ready-made Solutions TL SU a Utilising ready-made by eae al Pee ee eeu manufacturing operation we readily available in supply chain Efficiency of Assembly Reducing product assembly compl Ga Sur aed ¥ Offsite Production Aas Su eeDfMA Design Principles structura lS ttl ea Architectur mer oePrefabrication Continuum cy iresrrc] eas itd feo Tc Manpower distribution in a typical project Health & Safety 80% are from these major trades Formwork installation, Stel bar fing, concrete placement Structural 35%- 45% Wall Ting Painting, Door, Window, Cling Electrical system, Ar conditioning system, Plumbing sistem ‘Copyright© Bung and Consructon AuthorityBenefits and Advantages (Summary) 2"4 Construction Productivity Roadmap Focus « driving the adoption of DfMA PMN mic ieee asters Cul 8 Pee eee Tecra) prety reece heme ie oie Reece tacomplete with internal finishes, and fittings are manufactured in factories and transported to site for installation in a Lego-like manner Image: Crowne Plaza Hotel Y~inerease construction productivity, faster construction time Why PPVC reduce manpower on-site ¥ Safer working environment Reduced on-site dis-amenities & Concrete PPVC Steel PPVC Hotel, Hostel, Nursing Homeeon ee Structural \rchitectural MEP. FA ine! Sprinkler Dropper Prefab colng Module/ Prefab Pl er ars eee a PPVC is at the highest end of the DfMA continuum, and achieves highest site productivity=) Precast ieee ‘Structural Steel / Advanced Structural Continuum of Prefabrication & D{MA ree MET is part of the DiMA continuum and achieves high site productivity purposes. Examples of MET include Cross-Lominated Timber (CLT), Glued Lomincted Timber (Glulam) and Laminated Veneer Lumber (LVL). MET components can be prefabricated off-site in, factories to precise specifications and assembled on-site. Glued Laminated Timber (Glulam) oh eee eer eee etd Reet eee sere teary eee cece See eau era eee Cree nr Pace een See) cori Predominantly used for Pee ieared GMET has good fire-resistance due to the thick cross sections Fire protective measures with additional I" timber to protect inner material Conon Use of automatic fire sprinklers Protect wood with fire-grade board MET can be Designed to have Substantial Fire ResistancePaO CaO CSCO MCT lr cy: itn corn be termite free too! ee peor 4) Apply chemical treatment to the soil 5) Condit regular inspection for prescence of fermite 2) lnstell physical ba mndation and 2 a DfMA Technologies Continuum of Prefabrication & DfMIA Prefinished Surfaces On-site Dry Applied Finishes | — a i I 24 Class r {(Upper) 4 Prefabricated Bathroom Units (PBUs)PBU Guide BU implementation Integrated Sub: j Fully Integrated Assem a MET { Peve Gvanced Prefab Systems Structural Stel / Advanced | Precast / Hybrid 3" Class, Advanced Precast Systems (APCS)MECHANICAL pest “YSTEM / - MECHANICAL SYSTEM (Wire Rope Loop System) * Precast wall connecting system. PFEIFER VS*Box f ¢ “ Flexible cable loops PEIKKO PVL.ECHANICAL ‘SYSTEM - SPLICE SLEEVE Proprietary system used by our- Pressure grout overfiow > sleeve filed with grout IN- Pressure grout Sleeve Joint ~ casted inside the precast omponent Mechanical, Electrical and Plumbing (MEP) 108The MEP DfMA Continuum Ww ee 1 I High productivity improvement 1. MEP technologies at the higher end of DfMA continuum such as advanced / integrated sub- assemblies systems have higher potential to minimise downtime and waste on site, and improve health and safety 2. Current state of adoption by other GPEs a) Upcoming projects i. MOHH - Woodlands Health Campus (WHC) ii. SportSG - Sembawang Integrated Sports Hub 3. Currently exploring with HDB, Building Quality Group (BQG) to adopt advanced prefab systems / integrated sub-assemblies yi The MEP DfMA Continuum ke Ceiling Module Ceiling modules are suitable for common corridors or congested ceiling areas From BIM model to finished product The following MEP services could be integrated into such modules: - a) All forms of ducts, i.e. supply, exhaust, and fresh air b) Pipework, e.g. chilled water, potable water, non-potable water, sprinkler, hosereel, and dry riser ) Electrical and communication cabling, trunking and containment systemsThe MEP DfMA Continuum Plant modules Plant modules are suitable for MEP equipment e.g. chiller, AHU, pumps, and pipe headers From BIM model to finished product The MEP DfMA Continuum + Prefab Riser Module Riser modules are suitable for MEP risers, both in high-rise and underground developments _) € From BIM model to finished productExamples of MEP Technologies Across DfMA Continuudt neremental neal im of Prefabrication & DfMA (tii Integrated Comy Fully Integrated Components Prefab aincon metal Modular prefab rier with ltt | vith nan Phenolic dct ee ee © crowing aconton @ tocing adoption DfMA Technologies ** Multiple on-sit Structure of Engineered Wood Flooring 1. Finishing Layer (Factory Pre-coated)* 1 2, Hardwood Wear Layer (Commonly 2 known as Lamella) 3. Core Layer (Hardwood, Spruce or Compressed Plywood) 4, Back Layer (Plywood or Medium soft wood) ite coating is eliminated with the factory produced finishing layer. Engineered Wood Flooring 15 Steps Vs 3 Steps! Solid Timber Flooring EWFa ee) x cross Lamination vey POO™ ov ent CB esting Stability Factory Grading F Coating Resistance ; Joint Profiling Consistency in Tonality T Joint ARB) ost eee =e * ;od/ Spruce/ Check compatibility Nachum sot wood of wood layers = Good . Moisture Barrier Practices [torsos Subfloor Moisture Content (MC) <6% 0.0 ~ Subfloor Ns rir = Use of Moisture barrier if Subfloor an || Mc > 6% ‘ ia a ly mi nya “amDm " Projects with Successful use of EWF Successful use of EWF Projects withiatenionrte Sst Sea Esta Twin Peaks by Straits Construction by Hyundai No staining issue reported a Early Adoption Staining Encountered Reasons i Dripping “ Incompatible b Wet Subfloor Back Layer Mopping, Moisture s Content > 696 8) For sce ayer . vera mee a ty a ly aEngineered Wood Flooring GIP BCA has launched the Engineered Wood Flooring Good Industry Practices Guide ‘on 29 March 2016. ENGINEERED wood FLOORING Higher Adoption of Structural Steel For Buildings To Drive Construction Productivity )A. Use of Steel To Drive Productivity Steel as suitable alternative to RC for multi-storey buildings + Speed of construction — steel structures 30% to 40% faster Savings in foundation — reduction in building weight means shorter piles, contributed to time and cost savings Minimum storage of materials on-site — especially for commercial buildings in downtown planning area Architectural expression - building shape, long-span column-free spaces, slimmer columns Flexibility in space planning, more space for sale/ rental A. Use of Steel To Drive Productivity 1. Adoption of game changing technologies like ) PPVC/CLT/Gulam would help to achieve high construction productivity 2. Where projects could not adopt game _ changing technologies, steel would be the next viable option to achieve high construction productivity 3. High impact, high readiness for adoption 4, Productivity Impact at project level — Overall 10 to 20% in manpower and time savings 5. Cost impact at project level — generally 15 to 20%* higher locally “reference: cost competitiveness study on steel (Langdon Seah, 2013)How to bring in such game-changing technology...... tees Building Innovation Panel (BIP) Bringing in Productive Technologies - * Building Innovation Panel (BIP) Te cua uae eae CS) as Saintety Facilitates bringing in of innovative Revevetopmenr 2 technologies not used in Singapore AUTORETY HOUSING & sa aa etry Multi-agency, one-stop platform Ws MaNeSWER poe Fast-tracked evaluation of new Orus Ce ) Resolve regulatory hurdlesAcceptance Framework * en Floc Paint 100% ‘only final coat is allowed Door in ee ee “only door leaves allowed for on- site installation Wardrobe and Cabinets | 100%, only doors are allowed for on-site lation Ee Electrical sockets and | 100%, only light fittings allowed for on- light switches site installation Note: Extracted from Code of Practice on Buildability - 2017 Edition Acceptance Framework — Work Flow * __—_—_—-— | | =} | a | Learning Points from Local Projects 1. Need for early contractor involvement 2. Establish clear scope of work among all parties Hreadee, 3. To balance efficiency and cost (e.g. large modules will incur extra escort cost for transportation) ‘ 4. Proper cash flow planning upfront. Developers and contractors could discuss upfront on the payment schedule CHANGING HE WAY WE BUILD Learning Points from Local Projects 5. Beneficial to have all trades on board during the early i design stage SoM A Tae aerwessengs ata mi. allows for the PPVC specialist's inputs into ceca for better P technical solutions I i ii. Lesser variation due to more precise design with all the trades involved iii. Buildability and constructability improved with main contractor and specialist fabricator's early involvement CHANGING we BUILDGroup Discussion a: - Decide on a project (Residential / Commercial / Industrial) - Suggest DfMA that can be used in the project, - Provide outline of your DMA plan including design concept, production, installation - What are the considerations? - What are the benefits? - What are the challenges? 7a cy Group Discussion b: Use a building plan of a past or current project,preferably residential project, and covert it to modular construction. Show the module division and orientation : t * Your proposal shall take into account of PPVC design considerations such as: DIMA principles including choice of materials eg. stee/ concrete/athers Dimension considerations Ling and transportation considerations Water-seepage considerations Vertical and Horizontal connection of modules Alignment of lor finishes across the modules Continuity of MEP services across the modules Any others t 4 t