HVR talks to Bob Hughes, general manager of Pipe Centre’s Modular Engineering, about offsite pre-fabrication and asks why his division is growing apace along with the market.
Bob Hughes, general manager of Pipe Center's Modular Engineering, insists there is a decisive shift taking place.

'Buildings rely on complex systems of distributed pipework to carry chilled and hot water for air conditioning, heating and domestic services. If a system is not well designed and installed correctly, it can lead to an inefficient, unreliable and costly building,' he says.

'It is not surprising that the use of off-site assembled multi-service modules for building services projects is growing rapidly.'

Which is why Pipe Center's Modular Engineering business reports rapid growth in demand, as the benefits of off-site assembly of multi-service pipe work modules for buildings become increasingly understood.

With 35 years experience in the industry, and previous service with companies such as Balfour Kilpatrick and NG Bailey, Hughes has a track record in modular offsite solutions.

He joined Wolseley's Pipe Center just over a year ago, and has pioneered this new approach within the organisation.

With the launch of its Modular Engineering Business last year, Pipe Center claims to be the UK's first construction materials distributor to offer an offsite engineering service. The facility is based at a 30,000ft² factory in Worcester. Here, staff use a sophisticated computer-aided design and manufacturing system to produce modules for the smallest to the largest construction projects, which include all of the mechanical and electrical services required for the most complex buildings.

And the company will undertake work in all the disciplines: air conditioning, refrigeration, water, fire, ventilation, electrical supply, data and security.

Contracts to date include complete modular m&e solutions for a major regional healthcare facility, a shopping centre and prestigious office development.

For a regional primary care centre in the north of England, Pipe Center supplied more than 200 m&e modules.

'All elements of building services required in a building can be incorporated in a modular engineered system,' says Hughes.

'This includes pre-insulated heating, chilled and domestic water systems, electrical containment, ventilation ductwork, fire safety systems and so on.'

These are then put together in modular units which are assembled in factory-controlled conditions. A successful approach hinges on the use of integrated design and product-linked specification software.

'Using this, engineers can work quickly and accurately from original drawings to design a complete system for a proposed building.'

The operator selects the services required for a project via an on-screen tool pallet. The software then calculates the most economical widths and lengths, and renders the required services in modular form with full manufacturing data.

This is then fed directly into the offsite assembly process.

A database behind the software holds details of the full range of building services products available through Pipe Center and the wider Wolseley business.

The software automatically determines all the components and materials required, and delivers accurate costings and bills of materials. It also automatically generates pressure test certificates required.

The modules are assembled in sections of between 1.2 m and 6 m long. The materials and components required are then automatically analysed from the system design and selected from Pipe Center's catalogue, reducing wastage and eliminating ordering inefficiencies.

Underlining the point, Hughes pointed to a small, neat pile of products at the side of the factory. 'That is the waste from a full three-month's of production,' he says.

And operatives would go to this pile to check whether they could use these off-cuts for the next job before taking new materials from store.

Waste is not only a major source of inefficiency and avoidable cost, it adds to the environmental impact of a project,' says Bob Hughes. Most importantly, the client is charged only for what is used in the module.

Components are ordered in from Pipe Center and sent to the factory in the same way as it would deliver to large clients. And instead of dealing with dozens or even scores of suppliers, invoicing comes from one Pipe Center source.

Modular Engineering takes delivery of components, assembles the modules, adds its costs and the invoicing comes from Pipe Center. As you might expect with the savings clients are making, the concept has taken off.

'In cost terms, the modular approach offers substantial savings. It can shave 10 per cent off the costs of conventional on-site installation. And there are additional savings from reducing materials wastage and overcoming skilled labour shortages.'

And talking of skilled labour, Hughes says that he is willing to take on competent people and train them.

Intensive training

'There is an intensive training programme. New staff complete a basic training course which allows them to work on certain parts of the module. As the employee completes new training courses, he progresses to more complex work until, finally, he is able to work unsupervised on any unit,' says Hughes.

He says he is happy to take employees from any walk of life - not necessarily construction - who will fit in and want to work and learn.

Once completed, modules are delivered to site, positioned in their pro-determined locations and connected up to create a complete system.

And business, it seems, is booming.

Since the company started last year, with just seven employees on the factory floor, Hughes has had to double and treble that figure.

The concept of added value services provided by a distributor is evolving rapidly at Wolseley. Pipe Center is now working on developing its existing added-value services, such as off-site pipe fabrication at West Horndon, Essex, bespoke valve assembly by Valvestock in Fareham, and Climate Center's Custom Build facility for refrigeration and air conditioning plant in Newbury.