A new modular engineering facility is taking on the demand for off-site manufacture. And the modules are ticking the boxes when it comes to being environmentally friendly, meeting health and safety rules, and keeping deadlines
DEMAND from building services projects for modules that have been assembled off-site has been growing.

Factors causing this include growing awareness of corporate social responsibility, environmental issues, tough health and safety rules, and the need to deliver projects swiftly.

Construction products supplier Wolseley has launched a new operation within its Pipe Center business in Worcester, West Midlands, to meet the need for specifically-designed modules for building projects.

Bob Hughes was recently appointed general manager of the modular engineering facility. He has 35 years' experience in the industry, having worked with companies such as Balfour Kilpatrick and NG Bailey.

Complete system

The three hectare facility is equipped with computer-aided design and manufacturing systems, and is capable of designing and producing high-standard off-site-assembled modules for large construction projects.

Modules can include all building services, such as pre-insulated heating, chilled and domestic water systems, electrical containment, ventilation ductwork, and fire-safety systems.

Completed modules are transported to site and positioned in their designated locations. The modules are then connected up, to create a complete system.

At the heart of Pipe Center's approach to modularisedprojects is design and product specification software. This enables engineers to work from original drawings to design a complete system within a proposed building structure.

The system is then split up into industry-sized modules - of between 1.2m and 6m in length - that can be individually assembled. The software analyses a design, and automatically calculates the exact amount of materials and number of components required. This reduces wastage and eliminates ordering inefficiencies.

'The pressure to deliver a quality solution - to budget and on time - is constantly rising,' says Hughes.

'Modularisation and off-site assembly deliver on all of these. We are able to offer our customers a critical advantage - covering competitive component supply, design and manufacture of modules, and final delivery of modularised units direct to site - supported by Wolseley's established supply chain. It is an attractive proposition for companies looking to increase quality while reducing costs.'

He believes there are significant growth opportunities in the area, as more companies embrace modularisation. Key drivers are the ever-tighter timescales on projects, cost pressures, and the strict rules covering on-site health and safety.

Environmental pressures are driving the rise in the use of modularised solutions.

'The construction industry is undergoing a revolution in terms of the sustainability of materials and practices,' says Hughes. 'Waste is not only a source of inefficiency and cost - it adds to the environmental impact of a project.

'Because of the precision of the materials and the component specification, modularisation is a brilliant way of keeping the use of raw materials to a minimum, saving on cost and minimising the environmental impact of a construction project.'

Exciting initiative

The company has recruited 30 staff initially, to support the start-up of the business.
'We are delighted to have Bob Hughes on board and heading up this exciting initiative,' says Scott Craig, Pipe Center's sales director.

'I have no doubt modularisation is an important and growing trend in the industry, and the demand from customers will continue to increase in future.

'The benefits of pre-assembly in clean, controlled factory conditions are compelling. On grounds of quality, timeliness, cost and environmental protection, it is an approach that is hard to ignore.'