A host of solid business benefits can accrue from employing offsite assembly as building services contractor EIC South West discovered

As a building services contractor, EIC South West is only too familiar with the potential problems and inefficiencies that go with traditional onsite installation work.

However, says the company's design and build manager Chris Trew: 'The offsite modular engineering approach is a revelation. On practically every ground you can think of - cost, speed, quality, waste, timeliness, health and safety - it beats the traditional approach. I have no doubt that it is the future of building services design and installation.'

EIC South West is one of a new breed of building services providers pioneering the use of offsite assembly for buildings.

'Encountering offsite assembly for the first time, it can take a while to convince people of the benefits,' Mr Trew admits. 'The industry has been doing things the traditional way - with several trades on site - since the dawn of time. It takes something of a leap of imagination to see how it could be done differently.'

He adds: 'However, once main contractors, consultants and clients see the advantages for themselves, there is no going back. They are sold.'

Chris Trew has witnessed this process on a number of projects, where his company has chosen to deliver an offsite modular engineered solution, and persuaded clients to support the approach.

The first project was Pool Innovation Centre, Redruth, which had particular site constraints that would have made conventional onsite installation extremely difficult. This included a 150mm floor void for the building services.
'It was a very tight situation, which would have been virtually impossible with traditional installation techniques,' he says.

He recalls that, at that time, he had heard about a new approach, based on building multi-service modules in factory conditions offsite, then transporting the modules to site to be connected up. He visited Pipe Center's Modular Engineering facility in Worcester to see first hand how it was done.

The new 30,000 sq ft centre provides pristine factory conditions for the creation of modular racks, containing all the services needed for even the most complex buildings, from a small office block up to a modern hospital.

'I went back to the Worcester factory three or four times. It was a learning experience. It provided a stunning insight into what this exciting new approach required and the potential benefits.'

Convinced of the advantages, he put together a project team with Bob Hughes, general manager of Modular Engineering.

The first task was to persuade the client that the modular approach was the right solution. As part of this, Modular Engineering built sample services modules, which in fact were ones that would be used in the project, and transported them to Cornwall for a presentation to the client and consultant.
'It may seem a lot of trouble to go to, but there is really is no other way,' says Chris. 'You have to show people to properly explain the benefits. Once they see for themselves and the penny drops, it is full steam ahead.'

So it proved. EIC was given the go-head for a modular engineered solution, and detailed design and planning got under way.

'You have to approach offsite solutions in a quite different way. It provides the opportunity - and demands - that you do the detailed thinking for the design and execution of services upfront. You must plan and critique the design from the ground up, identifying and resolving issues as you go.'

This was detailed and careful work, requiring close co-operation and input from all sides of the project team. The relationship between contractor and the company providing the modular solution was key to a successful outcome.

'We have an excellent relationship and working process with the Modular Engineering team. As with any successful partnership, it is based on co-operation and trust.'

The services included in the Pool Innovation Centre included heating, hot and cold domestic water and electrical containment. The cost of the modular engineered solution delivered was substantially lower than competing approaches.

'The beauty of the planning and proving process is that site issues can be foreseen and accommodated in the solution. In the case of the Pool project, the modules were located precisely - to the mm - to ensure floor support pillars were allowed for later in the build.'

How much can an offsite approach save on traditional onsite installation?

'It depends on the exact nature and requirements of the project, but we have found it saves between 10 and 20 per cent,' says Chris.
But the benefits should not just be weighed in terms of cost alone, he believes. 'The time-saving on site can give the contractor a massive edge. With the modular innovation we can use our labour force more efficiently.

'Instead of a group of people huddled over a drawing onsite trying to figure out where each pipe and service goes, we have a series of factory-tested modules that are simply shipped to site, located in position and connected up. It simplifies the whole process and cuts the time right down.'

Since its first successful project using a modular approach, EIC has used it on two other projects since - a new school in mid-Cornwall, and a college in Devon.

While the initial attraction of the approach was lower cost, experience of working with it has alerted EIC to other important benefits.

'We are realising the less obvious advantages, particularly to our contracts team, such as easier and quicker installation; for our project managers, it saves huge amounts of time in organizing the first fix systems.

'There is also significantly reduced waste - as only components and materials needed for the job are used. Health and safety on site is improved with no hot works; mechanical lifting systems are designed for the particular project and implemented on site, reducing risk exponentially.'

Fast installation

On the recent school project, first fix had to be completed in ten weeks; EIC did it in four with the modular solution and investing in engineering the project up front. What is the next stage for modular offsite building services solutions?

'It is a new and rapidly developing field. Modular Engineering is constantly evolving and adding new capabilities - and we are integral to the process. We are looking at bringing other innovations into the mix - including new materials, components and even ductwork - and working with the Wolseley team to deliver true innovation to all EIC's projects.

'There are also opportunities around bespoke plant spaces and specialist systems, such as sprinkler and medi-gas systems, which can all be integrated into the solution.

'We believe that, one day, all building services projects will be delivered this way. It's an exciting and pioneering period in the industry - and it's great to be in the vanguard.'